Lexus RX400h, Hybrid 3 2006

Fuel Pressure Regulator

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure, as outlined in this section.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the front floor heat insulator no.3.
  8.  
  9. Remove the fuel tank protector sub-assembly no.1.
  10.  
  11. Separate parking brake cable assembly no.3.
  12.  
  13. Disconnect the fuel tank wire.
  14.  
  15. Remove the charcoal canister protector.
  16.  
  17. Disconnect the charcoal canister fuel hose.
  18.  
  19. Disconnect the fuel tank main tube subassembly.
  20.  
  21. Disconnect the breather lower tube.
  22.  
  23. Remove the fuel tank assembly.
  24.  
  25. Remove the fuel pump and gauge with the suction tube, as follows:
    1. Disconnect the fuel pump connector.
    2.  
    3. Disconnect the clamp and vapor pressure sensor connector.
    4.  

  26.  
  27. Remove the tube joint clip and clamp, and pull out the fuel pump tube.
    WARNING
    Check that there is no dirt or foreign matter around the fuel tube joint and after cleaning off any excess dirt, proceed with the work. Be careful not to allow dirt or foreign matter to scratch or come into contact with the fuel tube connector and fuel suction plate that are sealed by o-rings. Do not use any tools for this work. Do not bend or twist the nylon tube by force. Cover the disconnected fuel tube joint with a plastic bag. When the fuel tube joint and fuel suction plate are stuck, pinch the fuel tank tube with the fingers, and turn it carefully to release. Disconnect the fuel tank tube.

    1. Remove the 8 bolts, fuel tank vent tube set plate and fuel pump connector plate.
    2.  
    3. Pull out the fuel pump assembly from the fuel tank.
      NOTE
      Do not damage the fuel pump filter. Be careful not to bend the arm of the sender gauge.

    4.  
    5. Remove the gasket from the fuel suction tube.
    6.  

  28.  
  29. Remove vapor pressure sensor assembly, as follows:
    1. Remove the cover.
    2.  
    3. Remove the tube joint clip, and pull out the vapor pressure sensor.
    4.  

  30.  
  31. Remove fuel sender gauge assembly, as follows:
    1. Disconnect the fuel sender gauge connector.
    2.  
    3. Unlock the fuel sender gauge, then slide and remove it.
    4.  

  32.  
  33. Remove fuel suction plate sub-assembly:
    1. Disconnect the fuel pump connector.
    2.  
    3. Using a screwdriver with its tip wrapped with tape, disengage the 4 snap claws from claw holes, and pull out the fuel suction plate.
      NOTE
      Do not damage the fuel suction support.

    4.  

  34.  
  35. Remove fuel pump harness, as follows:
    1. Disconnect the connector.
    2.  
    3. Using a screwdriver, pry out the fuel pump harness.
    4.  

  36.  
  37. Remove fuel suction support no.2, as follows:
    1. Using a screwdriver with its tip wrapped with tape, disengage the 4 snap claws from the claw holes, and remove the fuel suction support.
      WARNING
      Do not damage the fuel suction support.

    2.  

  38.  
  39. Remove fuel pump cushion rubber, as follows:
    1. Remove the fuel pump cushion rubber from the fuel pump.
    2.  

  40.  
  41. Remove fuel pump and fuel filter assembly, as follows:
    1. Pull out the fuel pump from the fuel tank fuel filter.
    2.  

  42.  
  43. Remove fuel pressure with jet pump regulator assembly:
    1. Remove the fuel pressure with jet pump regulator assembly from the fuel tank fuel filter.
    2.  
    3. Remove the O-ring from the fuel pressure with jet pump regulator assembly.

      Click image to see an enlarged view

      Fig. Exploded view of the fuel pump and related components (1 of 2)



      Click image to see an enlarged view

      Fig. Exploded view of the fuel pump and related components (2 of 2)

    4.  

  44.  

To install:

  1. Install fuel pressure w/ jet pump regulator assembly, as follows:
    1. Apply a light coat of spindle oil or gasoline to a new o-ring, and install it.
    2.  
    3. Install the fuel pressure with jet pump regulator assembly to the fuel tank fuel filter.
    4.  

  2.  
  3. Install fuel pump and fuel filter assembly:
    1. Apply a light coat of spindle oil or gasoline to the o-ring of the fuel pump.
    2.  
    3. Push in the fuel pump to the fuel tank fuel filter.
    4.  

  4.  
  5. Install fuel pump cushion rubber:
    1. Install the fuel pump cushion rubber to the fuel pump.
    2.  

  6.  
  7. Install the fuel suction support no.2.
  8.  
  9. Install fuel pump harness and attach the connector.
  10.  
  11. Install fuel suction plate sub-assembly, as follows:
    1. Connect the fuel pump connector.
    2.  
    3. Install the fuel suction plate.
    4.  

  12.  
  13. Install fuel sender gauge assembly:
    1. Slide the fuel sender gauge to engage the claw.
    2.  
    3. Connect the fuel sender gauge connector.
    4.  

  14.  
  15. Install vapor pressure sensor assembly:
    1. Install the vapor pressure sensor assembly with the tube joint clip.
    2.  
    3. Install the cover.
    4.  

  16.  
  17. Install fuel pump and gauge with suction tube:
    1. Install a new gasket to the fuel pump assembly.
    2.  
    3. Install the fuel pump assembly.
    4.  
    5. Install the fuel tank vent tube set plate by aligning it with the cutout on the fuel pump assembly.
    6.  
    7. Install the fuel tank vent tube set plate and fuel pump connector plate with the 8 bolts. Tighten to 53 inch lbs. (6.0 Nm).
    8.  
    9. Connect the fuel tank main tube with the tube joint clip and clamp.
      NOTE
      Check that there are no scratches or foreign objects on the connecting part. Check that the fuel tube joint is inserted securely. Check that the tube joint clip is on the collar of the fuel tube joint. after installing the tube joint clip, check that the fuel tube joint is not pulled off.

    10.  
    11. Connect the fuel tank wire connector.
    12.  
    13. Connect the vapor pressure sensor connector and clamp.
    14.  

  18.  
  19. Install the fuel tank assembly.
  20.  
  21. Connect the breather lower tube,
  22.  
  23. Connect the fuel tank main tube sub-assembly.
  24.  
  25. Connect charcoal canister fuel hose.
  26.  
  27. Install charcoal canister protector.
  28.  
  29. Connect the fuel tank wire.
  30.  
  31. Install the parking brake cable assembly no.3.
  32.  
  33. Install the fuel tank protector sub-assembly no.1.
  34.  
  35. Install front floor heat insulator no.3.
  36.  
  37. Install exhaust pipe assembly center.
  38.  
  39. Connect the negative battery cable.
  40.  
  41. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  42.  
  43. Check for fuel leaks.
  44.  

 
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