Canada - Fuel System - Fuel Cap Sticks

Bulletin
0527

Issue Date
2002-08-30

Market
Canada

Reference
FU-02-001R

Model
ES300

Year Range
2003, 2002

Component
FU

Subject:
GAS CAP STICKS (REVISED)

Under certain conditions the gas cap on some 2002 and 2003 model year ES300 vehicles may stick and consequently become difficult to remove. Under these circumstances the gas cap should be replaced with a new updated part which will ease the removal of the cap.

APPLICABLE VEHICLES: 2002 and 2003 model year ES300 vehicles produced BEFORE the Production Change Effective VINs listed below.






PRODUCTION CHANGE INFORMATION:






PARTS INFORMATION:

REPLACEMENT PROCEDURE:

1. Remove the gas cap from the fill neck.
2. Remove the tether from the fuel door with side cutters or pliers.
3. Install the new tether in the hole on the fuel door from which the old tether was removed.
4. Replace the gas cap by inserting into the fill neck and tightening clockwise until there is a single click. This click indicates the cap is tight.

CUSTOMER ASSISTANCE:






Instructions for Proper Operation of the Gas Cap

Gas Cap Removal






1. To remove the fuel tank cap, turn the cap slowly counterclockwise for roughly 90 degrees of rotation until you start to feel a resistance.
(Although a click will be heard during turning, it does not indicate that the cap has been released.)






2. Then rotate the cap an additional 30 degrees or until the counterclockwise rotation can no longer continue.






3. At this stage, you should pause slightly before removing the cap. It is not unusual to hear a slight "swoosh" or "hiss" when the cap is opened.
The removed cap can be stored on the back side of the fuel filler door.

Gas Cap Installation
When installing the gas cap turn the cap clockwise until you hear one click. When you hear a click, the cap is fully closed. Do not turn further after the click.

NOTICE:
To remove or install the gas cap, apply turning force only - do not pull or pry it. Trying to pull or pry the cap can result in damage to the cap itself.

NOTE:
- If the cap is not tightened securely, the malfunction indicator lamp comes on. Make sure the cap is tightened securely.
- The indicator lamp goes off after driving several times. If the indicator lamp does not go off, contact your Lexus dealer as soon as possible.






REPAIR TIME:


NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.