Intake manifold LEXUS LS430 2003 Factory User Guide

Fig. 25: Installing Knock Sensor
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a. Install the 2 knock sensors with the 2 nuts, as shown in the illustration.
Torque: 20 N.m (204 kgf.cm, 15 ft,lbf)
b. Connect the 2 knock sensor connectors.
10.INSTALL INTAKE MANIFOLD ASSY

Fig. 26: Installing Intake Manifold Assy
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a. Place 2 new gaskets on the cylinder heads with the white mark facing outward.
b. Install the upper and lower intake manifolds assembly with the 6 bolts and 4 nuts.

Fig. 27: Installing Upper And Lower Intake Manifolds Assembly
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Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)
c. Connect the 8 injector connectors.
d. Install the engine wire protector (rear side) with the 2 bolts.

Fig. 30: Connecting VSV Connector For EVAP
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Torque: 7.5 N.m (76.5 kgf.cm, 66 in..lbf)
k. Install the V-bank cover bracket No. 2 with bolt.
Torque: 7.5 N.m (76.5 kgf.cm, 66 in..lbf)
l. Install the VSV for EVAP to the intake manifold with the bolt.
Torque: 7.5 N.m (76.5 kgf.cm, 66 in..lbf)
m. Connect the EVAP hose to the VSV for EVAP.
n. Connect the VSV connector for EVAP.
11.INSTALL THROTTLE BODY ASSY (See REPLACEMENT
)
12.INSTALL INTAKE AIR CONNECTOR PIPE
13.INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS (See ON
-VEHICLE
INSPECTION )
14.INSTALL V-BANK COVER
Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf)
15.CONNECT BATTERY NEGATIVE TERMINAL

2. Turn the crankshaft damper bolt to gain access to each bolt.
3. Hold the crankshaft damper bolt with a wrench, and remove the 6 bolts.
b. Remove the 10 bolts and ground strap.
c. Remove the transmission together with the torque converter clutch from the engine.
Fig. 39: Removing Flywheel Housing Under Cover

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48.REMOVE DRIVE PLATE & RING GEAR SUB-ASSY
a. Remove the 8 bolts, rear spacer, ring gear and front spacer.
49.INSTALL ENGINE STAND
50.REMOVE THROTTLE BODY ASSY (See REPLACEMENT
)
51.REMOVE INTAKE MANIFOLD ASSY
a. Disconnect the VSV connector for EVAP.
b. Disconnect the EVAP hose from the VSV for EVAP.
c. Remove the bolt, disconnect the VSV for EVAP from the upper intake manifold.
d. Remove the bolt and V-bank cover bracket No. 2.
e. Remove the bolt and V-
bank cover bracket No. 3.

Fig. 40: Removing Intake Manifold Assy
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f. Disconnect the VSV connector for ACIS.
g. Remove the bolt and V-bank cover bracket No. 1.
h. Remove the bolt and V-
bank cover fastener.

Fig. 41: Identifying VSV Connector For ACIS
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i. Remove the 4 bolts, and disconnect the engine wire protector (LH side) from the upper intake
manifold and camshaft bearing cap.
j. Disconnect the 2 wire clamps on the engine wire (RH side) from the brackets on the RH delivery
pipe.
k. Remove the 2 bolts, and disconnect the engine wire protector (rear side) from the rear water bypass
joint and RH cylinder head.

Fig. 42: Disconnecting Engine Wire Protector (LH Side) From Upper Intake Manifold
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l. Disconnect the 8 injector connectors.
m. Remove the 6 bolts, 4 nuts, intake manifold assy and 2 gaskets.
Fig. 43: Identifying Bolts

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52.INSPECT INTAKE MANIFOLD ASSY
a. Upper intake manifold:
Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head
for warpage.
Maximum warpage: 0.15 mm (0.0059 in.)

If the warpage is greater than the maximum, replace the manifold.
Fig. 44: Measuring Surface Contacting Cylinder Head

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b. Lower intake manifold Using a precision straight edge and feeler gauge, measure the surface
contacting the cylinder head for warpage.
Maximum warpage: 0.15 mm (0.0059 in.)
If the warpa
ge is greater than the maximum, replace the manifold.

Fig. 45: Identifying Lower Intake Manifold
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53.REMOVE STARTER ASSY (See REPLACEMENT
)