Posted 27 July 2012 - 09:35 AM
OK, here's how to replace the fuel filter on a 2002 SC430. I'm sure later years are the same. Obviously first order the parts. You'll need the filter, the pick up tube screen and you should probably get some clips if you're changing the pick up screen because you'll mangle the old one getting it off. Order a couple because they're cheap and I destroyed the old one getting it off and one new one putting it on. I bought two. If you're not changing the screen you don't need the clips. I'm told that the screen can be cleaned with brake cleaner but I replaced it while I had it all apart. Anyway, first, put the top down so you have room to work and then move the front seats all the way forward. Then I suggest that you disconnect the battery just in case of a spark and of course, no smoking or open flame. Take out the back seat by reaching under it on both sides and lift up. It will pop out fairly easily. On the drivers side you'll see a triangle plate with three plastic nuts and a wire running through it. Take off the nuts and lift. You can slide out the rubber grommet from where the wire runs to give you some play but the wires stay attached. Under the plate you'll see another plate with eight phillips head screws. They don't look like they had an edge for a socket but they do and I needed to put a socket on each of them to break them loose. Then unscrew with phillips head driver. The plate lifts off. Then there is a little plastic locking clip surrounding the fuel line connector. Slide the clip off (mine was yellow) and lift off the fuel line. You'll get some leakage here so this job is best done outdoors. At that point you can lift out the entire assembly. You have to reach in a bit to release the hose that comes from the opposite side of the fuel tank. Slide the clamp down and pull that hose off. Now you have two loose hoses, The main fuel line and the one that runs to the other side of the saddle fuel tank. Carefully lift out the whole thing without bending the sending unit wire. Once out you need to take it apart using two flat head screw drivers on the several plastic clips that hold the whole thing together. Once apart replace part for part from the old filter to the new. The entire fuel pump fits up inside the filter assembly. Once you get the wire connector off the fuel pump itself you can take the part out of the back seat area and have room to work. Assembly is the reverse. The only problem I had was that when it was all done and back together and the car running I noticed that the gas gauge was about a quarter of a tank too high. I had run the tank almost empty before the job. I took it apart again and noticed that the sending unit wire had come off the plastic clip near where the calibration adjustment was. I clipped that back together and reinstalled but the gauge was still wrong. I thought that maybe it takes the computer some time to average fuel level and went to fill the tank. After driving about a mile the gauge came back to where it was before I started the job. I don't know if this will fix my problem. Time will tell but I did see something that I think is strange. While I had it apart I opened up the secondary side of the fuel tank. Just a sending unit there. That side of the gas tank was dry!!!! The main side had several inches of gas in it even though the light on my gas gauge was on. So I'm thinking that maybe my problem was that the pickup on the main side was partially clogged and I was sucking air on occasion from the secondary side into the fuel line and that's what was causing my intermittent skip. Again, time will tell.