How to Install a Fuel Pump on a 1994 Lexus ES300

The fuel pump on the 1994 Lexus ES300 is located inside the fuel tank. A faulty fuel pump may cause hard starting, engine stalling or a no-start condition, which could leave you stranded. Before condemning the fuel pump, which can be a costly repair, check the fuse and relay that control the fuel pump to ensure they are functioning properly. If the fuel filter has not been recently replaced, it is best to replace it with the fuel pump to ensure adequate fuel delivery to the engine. Replacing the fuel pump can be accomplished quickly with a few simple hand tools.

Instructions

Fuel Pump Removal

1

Disconnect the negative battery cable with the socket and ratchet. Remove the fuel cap to relieve the tank pressure. Pull up on the lower section of the rear seat at the middle of each side. Once the latches release, hold the front of the seat up and slide the seat forward to remove it. Set the seat cushion aside.

2

Remove the screws that secure the fuel pump access cover to the floor using the Phillips screwdriver. Disconnect the electrical connector at the fuel pump. Remove the outlet pipe from the fuel pump using a line wrench.

3

Remove the remaining hoses at the fuel pump by squeezing the hose clamps with a pair of pliers and sliding the clamps back on the line. Pull the hoses off. Note their location so they can be replaced at the proper location. Remove the screws that secure the fuel pump bracket to the tank with a Phillips-head screwdriver. Carefully slide the fuel pump assembly out of the tank. Wrap the pump in shop rags to prevent dripping.

Fuel Pump Installation

4

Install the new gasket on the fuel pump. Gently lower the new fuel pump into the tank, positioning it at the same angle as the original. Tighten the fuel pump retaining screws to 34 inch-pounds.

5

Connect the fuel lines to the pump and reconnect the electrical connector. Install the fuel pump access cover.

6

Slide the back of the lower seat cushion under the bottom of the seat back until the clips engage. Line up the brackets at the front of the seat bottom to the holes in the floor. Press down firmly on the seat until it snaps to secure the seat bottom.

7

Install the fuel cap. Connect the negative battery cable. Cycle the key to the on position and back off several times to build fuel pressure. Start the engine and check for leaks. Test-drive the car to ensure it runs properly.