LEXUS LS430 2003 Factory Repair Manual

1.WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See PRECAUTION )
2.DISCONNECT BATTERY NEGATIVE TERMINAL
3.DRAIN FUEL (See PRECAUTION
)
4.REMOVE SEPARATE TYPE REAR SEAT CUSHION ASSY LH (SEPARATED TYPE REAR
SEAT) (See OVERHAUL
)
5.REMOVE BENCH TYPE REAR SEAT CUSHION ASSY (FIXED TYPE REAR SEAT) (See
OVERHAUL
)
6.REMOVE REAR FLOOR SERVICE HOLE COVER NO.2 (See REPLACEMENT
)
7.REMOVE FUEL TANK MAIN TUBE SUB-ASSY
a. Disconnect the connector in the fuel tank side.
1. Remove the tube joint clip.
2. Pull out the fuel main tube.
3. Plu
g the port of the fuel suction plate with a clean rubber cap.

Fig. 50: Disconnecting Connector In Fuel Tank Side
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
b. Disconnect the connector in the fuel pipe side.
1. Clean the pipe before the operation.
2. Pull out the connector, holding the claw of the retainer by thumb as shown in the illustration.
HINT:
Do not remove the retainer when it is reinstalled.

Fig. 51: Pulling Out Connector
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
c. Protect each connecting part from damage and contamination by covering it with a vinyl bag.
8.REMOVE REAR FLOOR SERVICE HOLE COVER
a. Remove the service hole cover and disconnect the fuel sender gauge connector.
9.REMOVE FRONT FLOOR BRACE CENTER (See OVERHAUL
)
10.REMOVE ENGINE UNDER COVER NO.2
11.REMOVE EXHAUST PIPE ASSY (See REPLACEMENT
)
12.REMOVE PROPELLER SHAFT HEAT INSULATOR
13.REMOVE FRONT FLOOR HEAT INSULATOR NO.1
a. Remove the 2 bolts and propeller shaft heat insulator.
14.REMOVE DIFFERENTIAL SUPPORT PROTECTOR NO.1
15.REMOVE DIFFERENTIAL SUPPORT PROTECTOR NO.2
16.REMOVE PROPELLER SHAFT ASSY (See OVERHAUL
)
17.REMOVE PARKING BRAKE CABLE ASSY NO.2 (See REPLACEMENT
)
18.REMOVE PARKING BRAKE CABLE ASSY NO.3 (See REPLACEMENT
)
19.REMOVE FUEL TANK TO FILLER PIPE HOSE
20.REMOVE FUEL TANK EVAPORATION VENT TUBE
21.REMOVE FUEL TANK BREATHER HOSE

22.REMOVE FUEL TANK ASSY
a. Using a mission jack, support the fuel tank.
b. Disconnect the fuel tank band No.1 and remove the fuel tank.
23.REMOVE FUEL TANK VENT TUBE SET PLATE
a. Remove the 8 bolts and set plate.
Fig. 52: Disconnecting Fuel Sub
-Suction Hose
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
24.REMOVE FUEL PUMP AND SENDER GAUGE ASSEMBLY
a. Lift up the fuel pump and sender gauge. Disconnect the fuel sub-suction hose from the fuel return
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25.REMOVE FUEL SENDER GAGE ASSY
26.REMOVE FUEL TANK PROTECTOR SUB-ASSY NO.1
27.REMOVE FUEL TANK BREATHER TUBE SUB-ASSY
28.REMOVE CHECK VALVE PROTECTOR
29.REMOVE FUEL TANK OVER FILL CHECK VALVE ASSY
Fig. 53: Removing Fuel Tank Over Fill

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
a. Insert a clip remover between the check valve and gasket, and remove the check valve pulling up
the valve little by little.
30.INSTALL FUEL TANK OVER FILL CHECK VALVE ASSY
a. Install a new
gasket to the fuel tank.

b. Apply some gasoline to the entire circumference of a new over fill check valve, and insert it into
the fuel tank without using excessive force. Take care not to drop the gasket into the tank.
c. Confirm that the over fill check valve is inserted without any clearance between the gasket and the
lower surface of the valve.
31.INSTALL CHECK VALVE PROTECTOR
32.INSTALL FUEL TANK CUSHION NO.1
a. Attach the fuel tank cushions to the areas marked with diagonal lines in the illustration.
Fig. 54: Identifying Fuel Tank Cushion

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
33.INSTALL FUEL TANK BREATHER TUBE SUB-ASSY
34.INSTALL FUEL TANK PROTECTOR SUB-ASSY NO.1
35.INSTALL FUEL SENDER GAGE ASSY
a. Inserting a new gasket in between, install the fuel sender gauge.
Torque: 1.5 N.m (15 kgf.cm, 13 in..lbf)
36.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. 55: Installing Fuel Sub-Suction Hose
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
37.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)
38.INSTALL FUEL TANK ASSY
a. Install the fuel tank with the fuel tank band.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
39.INSTALL FUEL TANK BREATHER HOSE
40.INSTALL FUEL TANK EVAPORATION VENT TUBE
41.INSTALL FUEL TANK TO FILLER PIPE HOSE
42.INSTALL PARKING BRAKE CABLE ASSY NO.3 (See REPLACEMENT
)
43.INSTALL PARKING BRAKE CABLE ASSY NO.2 (See REPLACEMENT
)
44.INSTALL PROPELLER SHAFT ASSY (See OVERHAUL
)

45.INSTALL DIFFERENTIAL SUPPORT PROTECTOR NO.2
46.INSTALL DIFFERENTIAL SUPPORT PROTECTOR NO.1
47.INSTALL FRONT FLOOR HEAT INSULATOR NO.1
a. Install the front floor heat insulator with the 4 bolts.
Torque: 5.4 N.m (55 kgf.cm, 47 in..lbf)
48.INSTALL PROPELLER SHAFT HEAT INSULATOR
49.INSTALL EXHAUST PIPE ASSY (See REPLACEMENT
)
50.INSTALL ENGINE UNDER COVER NO.2
51.INSTALL FRONT FLOOR BRACE CENTER (See OVERHAUL
)
52.INSTALL REAR FLOOR SERVICE HOLE COVER
53.INSTALL FUEL TANK MAIN TUBE SUB-ASSY
a. Connect the connector on the fuel tank side.
1. Attach the fuel tube connector to the port of the fuel suction plate.
2. Install the tube joint clip.
b. Connect the connector on the fuel pipe side.
1. Insert the connector by aligning the axes of the pipe and the connector until the retainer makes a
click sound.

Fig. 56: Connecting Connector
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
54.INSTALL REAR FLOOR SERVICE HOLE COVER NO.2 (See REPLACEMENT
)
55.INSTALL BENCH TYPE REAR SEAT CUSHION ASSY (FIXED TYPE REAR SEAT) (See
OVERHAUL
)
56.INSTALL SEPARATE TYPE REAR SEAT CUSHION ASSY LH (SEPARATED TYPE REAR
SEAT) (See OVERHAUL
)
57.ADD FUEL (See PRECAUTION
)
58.CONNECT BATTERY NEGATIVE TERMINAL

59.INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS (See ON-VEHICLE
INSPECTION )
60.CHECK FOR EXHAUST GAS LEAKS (See REPLACEMENT
)