Canada - Fuel System - Fuel Door Loose/Difficult To Close

Bulletin
TSB2597

Issue Date
September 30, 2008

Title
FUEL DOOR LOOSE OR DIFFICULT TO CLOSE

Component
VEHICLE EXTERIOR

Models
06 GS300, 06-07 GS430, 07-08 GS350 & GS450H, 08 GS460

INTRODUCTION:
Some Lexus GS customers may complain that the fuel door is difficult to close or feels loose when closed. An improved fuel filler pipe shield has been developed to correct this condition. Refer to the repair procedure below to replace the fuel filler pipe shield.






APPLICABLE VEHICLES:






PRODUCTION CHANGE INFORMATION:






PARTS INFORMATION:






WARRANTY INFORMATION:






REQUIRED SSTs:

REPAIR PROCEDURE:
1. Open the fuel door.
2. Remove the luggage compartment floor mat.
3. Remove the trunk opening finish trim.






A. Remove the 3 clips labeled A.
B. Detach the 4 clips to remove the finish plate.






4. Remove the LH luggage compartment trim cover. Using a plastic pry tool, remove the 3 clips and trim cover.

NOTE
Luggage compartment trim panel disassembly varies among GS models. Some removal of other panels may be necessary to remove the LH trim cover. Refer to the Repair manual within EETAS/ TIS library:
- Division: Lexus
- Model: GS300, GS430, GS350, GS450H, GS460
- Year: 2006 or 2007 or 2008 or 2009
- Service Category: Vehicle Exterior
- Section: Door/Hatch
- Keyword: Fuel lid opener motor assembly: Removal

5. Remove the fuel door opener motor cable from the retainer.






A. From inside the luggage compartment, locate the fuel door opener motor cable.
B. Turn the cable counterclockwise to remove.






6. Turn the cable lock retainer clockwise and remove from the fuel filler pipe shield.






7. Remove the 4 screws securing the fuel tank filler pipe shield.
8. Remove the fuel tank filler pipe shield and replace with the updated part.
9. Reinstall the 4 screws.






10. Reinstall the cable lock retainer and turn it






11. Reinstall the fuel door opener motor cable and turn the cable clockwise to lock.
12. Test the operation of the fuel door.
13. If the operation of the fuel door is normal, install the interior luggage compartment trim and mat. If the fuel door does not operate correctly continue to the next step.
14. Remove opener cable, lock retainer, and filler pipe shield again.






15. Adjust the sheet metal of the fuel door cable mount towards the front or rear of the vehicle to achieve correct operation (See Figure 8).

NOTE
Do NOT damage the protective coating of the sheet metal

16. Reinstall filler pipe shield, lock retainer and cable and retest. If operation is normal reinstall the interior luggage compartment trim and mat. If the fuel door does NOT operate correctly repeat the adjustment step.

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.