2003 LEXUS LS430 replacement

6.REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY NO.1 (SEE REPLACEMENT )
7.REMOVE INSTRUMENT PANEL CUP HOLDER ASSY (SEE REPLACEMENT
)
8.REMOVE CONSOLE UPPER REAR PANEL SUB-ASSY (SEE REPLACEMENT
)
9.REMOVE CONSOLE BOX CARPET (SEE REPLACEMENT
)
10.REMOVE REAR CONSOLE ARMREST ASSY (SEE REPLACEMENT
)
11.REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (SEE REPLACEMENT
)
12.REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER (SEE
REPLACEMENT
)
13.REMOVE CONSOLE PANEL SUB-ASSY UPPER (SEE REPLACEMENT
)
14.REMOVE CONSOLE BOX (SEE REPLACEMENT
)
15.SEPARATE OXYGEN SENSOR (SEE REPLACEMENT
)
16.REMOVE EXHAUST PIPE ASSY (SEE REPLACEMENT
)
17.REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (SEE OVERHAUL
)
18.DRAIN AUTOMATIC TRANSMISSION FLUID
a. Remove the drain plug, gasket and drain the ATF.
b. Install a new gasket and the drain plug.
Torque: 20 N.m (205 kgf.cm, 15 ft.lbf)
19.REMOVE AUTOMATIC TRANSMISSION FLANGE YOKE ASSY
a. Using SST and a hammer, loosen the staked part of the nut.
SST 09930-00010
HINT:
Move the shift lever to the P position.

Fig. 98: Staking Nut
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
24.INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (SEE OVERHAUL
)
25.FULLY TIGHTEN CENTER SUPPORT BEARING ASSY NO.1 (SEE OVERHAUL
)
26.INSTALL EXHAUST PIPE ASSY (SEE REPLACEMENT
)
27.ADD AUTOMATIC TRANSMISSION FLUID (SEE ADJUSTMENT
)
Fluid type: ATF WS
Capacity: 1.7 liters (1.8 US qts, 1.5 Imp.qts)
ON-VEHICLE INSPECTION
1.CHECK SHIFT LOCK OPERATION
a. Move the shift lever to the P position.
b. Turn the ignition switch to the LOCK position.
c. Check that the shift lever cannot be moved to any position other than P.
d. Turn the ignition switch to the ON position, depress the brake pedal and check that the shift lever
can be moved to another position.

OVERHAUL
1.DISCONNECT BATTERY NEGATIVE TERMINAL
2.REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.2 (SEE REPLACEMENT
)
3.REMOVE CHOKE KNOB HOLE COVER (SEE REPLACEMENT
)
4.REMOVE GLOVE COMPARTMENT PLATE (SEE REPLACEMENT
)
5.REMOVE INSTRUMENT PANEL GARNISH SUB-ASSY LH (SEE REPLACEMENT
)
6.REMOVE INSTRUMENT PANEL FINISH PANEL (SEE REPLACEMENT
)
7.REMOVE INSTRUMENT CLUSTER FINISH PANEL (SEE REPLACEMENT
)
8.REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (SEE REPLACEMENT
)
9.REMOVE PANEL INSTRUMENT CLUSTER FINISH LOWER (SEE REPLACEMENT
)
10.REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1 (SEE REPLACEMENT
)
11.REMOVE COIN BOX ASSY (SEE REPLACEMENT
)
12.REMOVE INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER (SEE
REPLACEMENT
)
13.REMOVE CIGAR LIGHTER HOLE BEZEL (SEE REPLACEMENT
)
14.REMOVE INSTRUMENTAL CLUSTER FINISH PANEL END (SEE REPLACEMENT
)
15.REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY NO.1 (SEE REPLACEMENT
)
16.REMOVE REAR CONSOLE ARMREST ASSY (SEE REPLACEMENT
)
17.REMOVE CONSOLE BOX PLATE (SEE REPLACEMENT
)
18.REMOVE INSTRUMENT PANEL CUP HOLDER ASSY (SEE REPLACEMENT
)
19.REMOVE CONSOLE BOX (SEE REPLACEMENT
)
20.REMOVE CONSOLE BOX DUCT NO.1 (SEE REPLACEMENT
)
21.SEPARATE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSY
a. Remove the nut and separate the floor shift gear shifting rod sub-assy.
22.REMOVE FLOOR SHIFT ASSY
a. Disconnect the connector.
b. Disconnect the indoor electrical key oscillator connector. (w/smart key)

3.REMOVE SEAT TRACK COVER LH
4.REMOVE SEAT TRACK BRACKET COVER OUTER FR
5.REMOVE SEAT TRACK BRACKET COVER INNER FR
6.REMOVE FRONT SEAT ASSY LH
7.REMOVE INSTRUMENT CLUSTER FINISH PANEL END
8.REMOVE INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER
9.REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1 (SEE REPLACEMENT
)
10.REMOVE COIN BOX ASSY
11.REMOVE OUTER MIRROR SWITCH ASSY
12.REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY NO.1 (SEE REPLACEMENT
)
13.REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY No.2 (SEE REPLACEMENT
)
14.REMOVE FR DOOR SCUFF PLATE LH (SEE REPLACEMENT
)
15.REMOVE FLOOR CARPET ASSY FRONT
16.CHECK AND ADJUST BRAKE PEDAL HEIGHT
a. Check brake pedal height.
Pedal height from asphalt sheet:
165.1 to 175.1 mm (6.49 to 6.89 in.)
b. If necessary, adjust brake pedal height.
1. Disconnect the connector from the stop lamp switch assy.
2. Loosen the stop lamp switch lock nut and remove the stop lamp switch assy.
3. Loosen the push rod lock nut.
4. Adjust the pedal height by turning the pedal push rod.
5. Tighten the push rod lock nut.
Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
6. Install the stop lamp switch assy.
7. Connect the stop lamp switch assy connector.
8. Push the brake pedal in 5 to 10 mm (0.20 to 0.39 in.), and turn the stop lamp switch assy to lock the
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9. After installation, push the brake pedal in 5 to 10 mm (0.20 to 0.39 in.), and check that the stop
lamp comes on.
10. Tighten the stop lamp switch lock nut.
Torque: 17 N.m (173 kgf.cm, 12 ft.lbf)
If the stop lamp does not come on, repeat the steps in (
b).

a. Release the parking brake pedal.
b. With the engine running, depress the pedal and measure the pedal reserve distance, as shown in the
illustration.
Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 105 mm (4.13 in.)
If incorrect, troubleshoot the brake system.
Fig. 19: Checking Pedal Reserve Distance

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
19.INSTALL FLOOR CARPET ASSY FRONT
20.INSTALL FR DOOR SCUFF PLATE LH (SEE REPLACEMENT
)
21.INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.2 (SEE REPLACEMENT
)
22.INSTALL INSTRUMENT PANEL UNDER SAFETY PAD SUB-ASSY NO.1 (SEE
REPLACEMENT
)

23.INSTALL OUTER MIRROR SWITCH ASSY
24.INSTALL COIN BOX
25.INSTALL INSTRUMENT PANEL UNDER COVER NO.1 (SEE REPLACEMENT
)
26.INSTALL CLUSTER FINISH PANEL CENTER LOWER
27.INSTALL INSTRUMENT CLUSTER FINISH PANEL END
28.INSTALL SEAT ASSY FR LH
29.INSTALL SEAT TRACK BRACKET COVER INNER FRONT
30.INSTALL SEAT TRACK BRACKET COVER OUTER FRONT
31.INSTALL SEAT TRACK OUTER COVER LH
32.INSTALL SEAT TRACK COVER RH
33.INSTALL SEAT BELT ANCHOR COVER CAP LH
OVERHAUL
1.DISCONNECT BATTERY NEGATIVE TERMINAL
2.PLACE FRONT WHEELS FACING STRAIGHT AHEAD
3.REMOVE SWITCH & VOLUME CASE
4.REMOVE STEERING WHEEL COVER LOWER NO.2
5.REMOVE HORN BUTTON ASSY (SEE OVERHAUL
)
6.REMOVE STEERING WHEEL ASSY (SEE OVERHAUL
)
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7.REMOVE STEERING COLUMN COVER (SEE OVERHAUL
)
8.REMOVE SPIRAL CABLE SUB-ASSY (SEE REPLACEMENT
)
9.REMOVE TURN SIGNAL SWITCH ASSY (SEE REPLACEMENT
)
10.REMOVE INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER
11.REMOVE INSTRUMENT CLUSTER FINISH PANEL END
12.REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1 (SEE REPLACEMENT
)
13.REMOVE COIN BOX ASSY
14.REMOVE OUTER MIRROR SWITCH ASSY
15.REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY NO.1 (SEE REPLACEMENT
)
16.REMOVE INSTRUMENT PANEL AIR BAG ASSY LOWER NO.1 (SEE REPLACEMENT
)
17.REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.2 (SEE REPLACEMENT
)
18.REMOVE INSTRUMENT CLUSTER FINISH PANEL (SEE REPLACEMENT
)
19.REMOVE COMBINATION METER ASSY (SEE OVERHAUL
)
20.REMOVE PUSH ROD PIN
a. Disconnect the stop lamp switch connector and brake pedal load sensing switch connector.

34.CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE ON-VEHICLE INSPECTION )
35.CHECK PEDAL FREE PLAY (SEE ON
-VEHICLE INSPECTION )
36.CHECK PEDAL RESERVE DISTANCE (SEE ON
-VEHICLE INSPECTION )
37.INSTALL COMBINATION METER ASSY (SEE OVERHAUL
)
38.INSTALL INSTRUMENT CLUSTER FINISH PANEL (SEE REPLACEMENT
)
39.INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.2 (SEE REPLACEMENT
)
40.INSTALL INSTRUMENT PANEL AIR BAG ASSY LOWER NO.1 (SEE REPLACEMENT
)
41.INSTALL INSTRUMENT PANEL SAFETY PAD SUB-ASSY NO.1 (SEE REPLACEMENT
)
42.INSTALL OUTER MIRROR SWITCH ASSY
43.INSTALL COIN BOX ASSY
44.INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSY NO.1 (SEE REPLACEMENT
)
45.INSTALL INSTRUMENT CLUSTER FINISH PANEL CENTER LOWER
46.INSTALL INSTRUMENT CLUSTER FINISH PANEL END
47.INSTALL TURN SIGNAL SWITCH ASSY (SEE REPLACEMENT
)
48.INSTALL SPIRAL CABLE SUB-ASSY (SEE REPLACEMENT
)
49.INSTALL STEERING COLUMN COVER (SEE OVERHAUL
)
50.INSTALL STEERING WHEEL ASSY (SEE OVERHAUL
)
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51.INSTALL HORN BUTTON ASSY (SEE OVERHAUL
)
52.INSTALL STEERING WHEEL COVER LOWER NO.2
53.INSTALL SWITCH & VOLUME CASE
54.CONNECT BATTERY NEGATIVE TERMINAL
55.INSPECT SRS WARNING LIGHT (SEE DIAGNOSIS SYSTEM
)
56.PERFORM INITIALIZATION (SEE PRECAUTION
)
OVERHAUL
1.REMOVE ENGINE ROOM SIDE COVER
2.SEPARATE ENGINE ROOM NO.3 R/B
a. Remove the bolt and separate the engine room No.3 R/B.
3.DRAIN BRAKE FLUID
a. Draw out fluid with syringe.
4.REMOVE BRAKE MASTER CYLINDER SUB-ASSY
a. Remove the clamp from the 2 brake tubes.

Fig. 57: Inspecting Vacuum Check Valve
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REPLACEMENT
1.REMOVE ENGINE ROOM SIDE COVER
2.SEPARATE ENGINE ROOM NO.3 R/B
a. Remove the bolt and separate the engine room No.3 R/B.
3.DRAIN BRAKE FLUID
a. Draw out fluid with syringe.
4.REMOVE BRAKE MASTER CYLINDER SUB-ASSY
a. Remove the clamp from the 2 brake tubes.