LEXUS LS430 2003 Factory Repair Manual

Fig. 41: Identifying VSV Connector For ACIS
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
l. Disconnect the 8 injector connectors.
m. Remove the 6 bolts, 4 nuts, intake manifold assy and 2 gaskets.
Fig. 43: Identifying Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
53.REMOVE STARTER ASSY (See REPLACEMENT
)

54.REMOVE GENERATOR ASSY (See REPLACEMENT )
55.REMOVE WATER INLET HOUSING
a. Remove the 2 bolts and inlet housing.
56.REMOVE WATER BYPASS JOINT FR
a. Disconnect the ECT sensor connector.
b. Remove the 4 nuts, water bypass joint and 2 gaskets.
Fig. 46: Identifying Water By
-Pass Joint FR
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
57.REMOVE WATER BYPASS JOINT RR
a. Disconnect the heater inlet hose from the water bypass joint.
b. Remove the 4 nuts, water bypass joint and 2 gaskets.

Fig. 47: Removing Water By-Pass Joint RR
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
58.REMOVE WATER BYPASS PIPE SUB-ASSY
a. Disconnect the heater outlet hose from the water bypass pipe.
b. Disconnect the wire clamp (for knock sensor bank 1, 2) from the bracket of the water bypass pipe.
c. Remove the bolt.
d. Pull out the water bypass pipe from the water pump.
e. Remove the O-ring from the water bypass pipe.
59.REMOVE OIL LEVEL GAGE GUIDE
60.REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
61.REMOVE CAMSHAFT POSITION SENSOR
62.REMOVE VVT SENSOR
63.REMOVE KNOCK SENSOR
a. Disconnect the 2 knock sensor connectors.
b. Remove the 2 nuts and 2 knock sensors.

Fig. 48: Identifying Knock Sensor Connectors
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
64.REMOVE ENGINE HANGER NO.1
65.REMOVE ENGINE HANGER NO.2
66.REMOVE IGNITION COIL ASSY
67.REMOVE OIL FILTER BRACKET SUB-ASSY
a. Disconnect the oil pressure switch connector.
b. Remove the stud bolt, 2 nuts and oil filter bracket with gasket.
68.REMOVE CRANKSHAFT POSITION SENSOR
69.REMOVE ENGINE OIL LEVEL SENSOR
70.REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
71.REMOVE EXHAUST MANIFOLD SUB-ASSY RH
a. Remove the 8 nuts, exhaust manifold and
gasket.

Fig. 49: Identifying Exhaust Manifold Sub-Assy RH
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
72.INSPECT EXHAUST MANIFOLD SUB-ASSY RH
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head
for warpage.
Maximum warpage: 0.50 mm (0.0197 in.)
If the warpa
ge is greater than the maximum, replace the manifold.

Fig. 50: Measuring Surface Cylinder Head
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
73.REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2
74.REMOVE EXHAUST MANIFOLD SUB-ASSY LH
a. Remove the 8 nuts, exhaust manifold and
gasket.