LEXUS LS430 2003 Factory Repair Manual

Fig. 40: Disconnecting Snap Claws From Claw Holes
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
12.REMOVE FUEL PRESSURE W/JET PUMP REGULATOR ASSY
a. Disconnect the fuel return jet tube from the clamp of the fuel filter.
b. Pull out the fuel pressure regulator from the fuel filter, and remove the fuel pressure regulator and
fuel return jet tube.
c. Remove the O-rin
g from the fuel pressure regulator.

Fig. 41: Disconnecting Fuel Return Jet Tube From Clamp Of Fuel Filter
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
13.REMOVE FUEL SUCTION PLATE W/SENDER GAUGE
a. Using 2 screwdrivers, disconnect the 4 snap claws from the claw holes and remove the fuel filter.

Fig. 42: Disconnecting Snap Claws From Claw Holes
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
b. Disconnect the fuel pump connector.
c. Remove the O-ring from the fuel port of the fuel suction plate.
14.REMOVE FUEL PUMP FILTER
a. Remove the clip and filter.
15.REMOVE FUEL PUMP ASSY
a. Pull out the fuel pump.
b. Remove the seal and spacer from the fuel pump.
16.INSTALL FUEL PUMP ASSY
a. Apply some gasoline to a new seal.
b. Install the spacer and a new seal to the fuel pump.
c. Push in the fuel pump.
17.INSTALL FUEL PUMP FILTER
a. Install the filter with a new clip.
18.INSTALL FUEL SUCTION PLATE W/SENDER GAUGE

a. Apply a light coat of gasoline to a new O-ring, and install it to the fuel port of the fuel suction plate.
b. Connect the fuel pump connector.
c. Push the fuel filter, and attach the 4 snap claws to the claw holes.
Fig. 43: Installing Snap Claws To Claw Holes

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
19.INSTALL FUEL PRESSURE W/JET PUMP REGULATOR ASSY
a. Apply a light coat of gasoline to a new O-ring, and install it to the fuel pressure regulator.
b. Push in the fuel pressure regulator to the fuel filter.
c. Check that the fuel pressure regulator rotates smoothly.
If it does not rotates smoothly, the O-ring may be pinched. Remove the fuel pressure regulator and
perform steps (b) and (c) above.
d. Connect the fuel return
jet tube to the clamp of the fuel filter.

Fig. 44: Installing Fuel Pressure Regulator
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
20.INSTALL FUEL PUMP CUSHION RUBBER
21.INSTALL FUEL SUCTION SUPPORT NO.2
a. Push the fuel suction support, and attach the 3 snap claws to the claw holes.

Fig. 45: Pushing Fuel Suction Support
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
22.INSTALL FUEL PUMP AND SENDER GAUGE ASSEMBLY
a. Install a new gasket to the fuel suction plate.
b. Connect the fuel sub-suction hose to the fuel return jet tube.
c. Attach the fuel pump and sender
gauge to the fuel tank.

Fig. 46: Installing Fuel Sub-Suction Hose
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
23.INSTALL FUEL TANK VENT TUBE SET PLATE
a. Install the set plate with the 8 bolts.
Torque: 6.0 N.m (61 kgf.cm, 52 in..lbf)
24.INSTALL FUEL TANK MAIN TUBE SUB-ASSY
a. Attach the fuel tube connector to the port of the fuel suction plate.
b. Install the tube joint clip.

Fig. 47: Installing Fuel Tube Connector
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
25.INSTALL REAR FLOOR SERVICE HOLE COVER NO.2
Install the service hole cover with the 3 cap nuts.

Fig. 48: Installing Service Hole Cover
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
26.INSTALL BENCH TYPE REAR SEAT CUSHION ASSY (FIXED TYPE REAR SEAT) (See
OVERHAUL
)
27.INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSY LH (SEPARATED TYPE REAR
SEAT) (See OVERHAUL
)
28.ADD FUEL (See PRECAUTION
)
29.CONNECT BATTERY NEGATIVE TERMINAL
30.INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS (See ON
-VEHICLE
INSPECTION )
COMPONENTS

Fig. 49: Exploded View Of Fuel Tank Assy Components
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REPLACEMENT