Lexus LS430 Fuel Pump Replacement

Lexus LS430 Fuel Pump Replacement

Lexus Fuel Pump Replacement Feature

We will use a third-generation 2006 Lexus LS430 as our case study for this fuel pump assembly replacement. First, discharge the fuel system pressure, disconnect the negative battery terminal and drain the fuel. Be sure to remove the rear seat cushion assembly. Consult the owner’s manual for the above tasks.

Lexus Fuel pump replacement fig 1
Fig. 1.

1. Remove the rear floor service hole cover No. 2. Remove the three cap nuts and service hole cover. See Fig. 1.

2. Remove the fuel tank main tube subassembly.
a. Remove the tube joint clip;
b. Pull out the fuel tank main tube;
c. Plug the port of the fuel ­suction plate with a clean rubber cap. See Fig. 2.

Some notes: These procedures should be performed with the fuel tank less than 1/4 full. Be sure to check for dirt contamination in the pipe, on the pipe seal surface and around the connector, and clean them if necessary. Foreign matter can damage the O-ring or cause leaks in the seal between the pipe and connector.

Lexus Fuel Pump Replacement Fig 2
Fig. 2.

Do not use any tools in these procedures, and do not forcefully bend or twist the nylon tube. Put the pipe and connector ends in vinyl bags to prevent damage and dirt contamination.
If the pipe and connector are stuck together, pinch the tube ­between your fingers and turn it carefully to free them. Then ­disconnect the tube.

3. Remove the fuel tank vent tube set plate. ­Remove the eight bolts and then the set plate.

Lexus Fuel Pump Replacement Fig 3
Fig. 3.

4. Remove the fuel pump and sender gauge ­assembly. Lift up the fuel pump and sender gauge. Then, disconnect the fuel sub-suction hose from the fuel return jet tube and remove the fuel pump, sender gauge and gasket. Do not damage the fuel pump filter, and be careful not to bend the arm of the sender gauge. See Fig. 3.

5. Remove fuel suction support No. 2. The proper technique is to use two screwdrivers, disconnect the three snap claws from the claw holes and remove the fuel suction support. Be careful not to damage the suction support and fuel filter. See Fig. 4.

6. Remove the fuel pump cushion rubber.

Lexus Fuel Pump Replacement Fig 4
Fig. 4.

7. Remove fuel pressure with the jet pump regulator ­assembly.
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. See Fig. 5.
c. Remove the O-ring from the fuel pressure regulator.

8. Remove the fuel suction plate with sender gauge.

a. Using two screwdrivers, disconnect the four snap claws from the claw holes and remove the fuel filter (see Fig. 6). Be careful not to damage the filter assembly and suction plate.
b. Disconnect the fuel pump connector.
c. Remove the O-ring from the fuel port of the fuel suction plate.

Lexus Fuel Pump Replacement Fig 5
Fig. 5.

9. Remove the fuel pump ­filter. Remove the clip and the filter.

10. Remove the fuel pump assembly.
a. Pull out the fuel pump.
b. Remove the seal and spacer from the fuel pump.

Lexus Fuel Pump Replacement Fig 6
Fig. 6.

11. Install the fuel pump assembly.
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.

12. Install the fuel pump filter. Install it using a new clip.

13. Install the fuel suction plate with a sender gauge.
a. Apply a light coat of gasoline to a new O-ring, and install it into the fuel port of the fuel ­suction plate.
b. Connect the fuel pump ­connector.
c. Push in the fuel filter and ­attach the four snap claws to the claw holes. See Fig. 7.

Lexus Fuel Pump Replacement Fig 7
Fig. 7.

14. Install the fuel pressure regulator with the jet pump regulator assembly.
a. Apply a light coat of gasoline to a new O-ring, and install it into 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 the regulator does not rotate smoothly, the O-ring may be pinched. Remove the fuel ­pressure regulator and perform the two steps above.
d. Connect the fuel return jet tube to the clamp of the fuel ­filter. See Fig 8.

15. Install the fuel pump cushion rubber.

Lexus Fuel Pump Replacement Fig 8
Fig. 8.

16. Install the fuel suction support No. 2.
Push the fuel suction support, and attach the three snap claws to the claw holes. See Fig. 9.

17. Install the 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. See Fig. 10.
c. Attach the fuel pump and sender gauge to the fuel tank.

Lexus Fuel Pump Replacement Fig 9
Fig. 9.

18. Install the fuel tank vent tube set
plate.
a. Install the set plate with the eight bolts. Torque: 6.0 Nm (61 kgf ⋅cm, 52 in.-lbf.).

Lexus Fuel Pump Replacement
Fig. 10.

19. Install the fuel tank main tube ­sub-
assembly.
a. Attach the fuel tube connector to the port of the fuel suction plate.
b. Install the tube joint clip. See Fig. 11.

20. Install the rear floor service hole cover No. 2. Install the service hole cover with the three cap nuts.

21. Install the rear seat cushion assembly.

22. Add fuel.

Lexus Fuel Pump Replacement
Fig. 11.

23. Connect the battery negative terminal.

24. Inspect fuel pump operation and check for fuel leaks.

Information courtesy of MotoLOGIC® Repair & ­Diagnostics.

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