LEXUS LS430 2003 Factory Repair Manual

Fig. 3: Fuel System - System Diagram (2 Of 3)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 4: Fuel System - System Diagram (3 Of 3)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
PRECAUTION
1.BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE
FROM BATTERY
2.DO NOT SMOKE OR WORK NEAR AN OPEN FLAME WHEN WORKING ON FUEL

SYSTEM
3.KEEP GASOLINE AWAY FROM RUBBER AND LEATHER PARTS
4.DISCHARGE FUEL SYSTEM PRESSURE
a. Using the F/PMP relay:
1. Remove the engine room R/B cover upper.
2. Remove the F/PMP relay.
3. Start the engine.
4. After the engine has stopped, turn the ignition switch OFF.
5. Crank the engine. Check that the engine does not start.
6. Remove the fuel tank cap to discharge pressure from the fuel tank.
7. Disconnect the negative (-) battery terminal cable.
8. Reinstall the F/PMP relay.
b. Using the fuel pump connector:
1. Remove the rear seat cushion.
2. Remove the rear floor service hole cover.
3. Disconnect the fuel pump connector.
4. Start the engine.
5. After the engine has stopped, turn the ignition switch OFF.
6. Crank the engine. Check that the engine does not start.
7. Remove the fuel tank cap to discharge pressure from the fuel tank.
8. Disconnect the cable from the negative (-) battery terminal.
9. Reconnect the fuel pump connector.
10. Install the rear floor service hole cover.
11. Install the rear seat.

5.FUEL SYSTEM
a. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out. Observe
these procedures:
1. Perform the "DISCHARGE FUEL SYSTEM PRESSURE" procedures above. Put a container
under the connection.
2. Disconnect the fuel tube.
3. Drain the fuel remaining inside the fuel tube.
4. Protect the disconnected fuel tube from damage and foreign material by covering it with a
plastic bag.
b. When connecting the union bolt (fuel pressure pulsation damper) on the high pressure pipe union,
observe these procedures:
1. Always use 2 new gaskets.
2. Tighten the union bolt by hand.
Fig. 5: Tightening Union Bolt By Hand

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. Using SST, tighten the union bolt to the specified torque.
SST 09612-24014 (09617-24011)
Torque:

33 N.m (340 kgf.cm, 24 ft.lbf) for use with SST
39 N.m (400 kgf.cm, 29 ft.lbf)
Fig. 6: Tightening Union Bolt To Specified Torque

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
c. Observe these precautions when removing and installing the injector.
1. Never reuse the O-ring.
2. When placing a new O-ring on the injector, take care not to damage it.
3. Coat a new O-ring with spindle oil or gasoline before installing. Never use engine, gear or
brake oil.

Fig. 7: Installing O-Ring With Spindle Oil Or Gasoline
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
d. Install the injector to the delivery pipe and the lower intake manifold as shown in the illustration.
Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe or
intake manifold touches O-ring of the injector.

Fig. 8: Installing Injector To Delivery Pipe And Lower Intake Manifold
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
e. Observe these precautions when disconnecting the fuel tube connector (quick type):
1. Disen
gage the lock claw by lifting up the cover, as shown in the illustration.

Fig. 9: Lifting Up Cover, Disengaging Lock Claw
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2. If the connector and pipe are stuck, pinch the connector, and push and pull the pipe to
disconnect them. Do not use any tools.
3. Check for forei
gn matter on the seal surface of the disconnected pipe. Clean it if necessary.

Fig. 10: Pinching Connector
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
4. To protect the disconnected pipe and connector from damage and foreign matter, cover it
with a plastic bag.

Fig. 11: Covering Disconnected Pipe And Connector With Plastic Bag
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
f. Observe these precautions when connecting the fuel tube connector (quick type).
1. Check that there is no damage or foreign matter on the part of the pipe that contacts the
connector.
2. Align the axis of the connector with the axis of the pipe. Push the pipe into the connector
until the connector makes a `click' sound. If the connection is too tight, apply a small amount
of fresh engine oil on the tip of the pipe.
Fig. 12: Aligning Axis Of Connector With Axis Of Pipe

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. After connecting the pipe and connector, try to pull them apart to confirm that they are
securely connected.
4. Install the No. 1 fuel pipe clamp to the connector.