LEXUS LS430 2003 Factory Repair Manual

Fig. 286: Removing Upper And Lower Intake Manifold Assembly
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
10.REMOVE INTAKE MANIFOLD ASSY
a. Remove the 6 bolts, 4 nuts, upper and lower intake manifold assembly and 2 gaskets.
11.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. 287: Disconnecting Heater Inlet Hose From Water By
-Pass Joint
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
12.REMOVE WATER INLET HOUSING
a. Remove the 2 bolts and inlet housing.
13.REMOVE WATER BYPASS JOINT FR
a. Disconnect the ECT sensor connector.
b. Remove the 4 nuts, water bypass joint and 2 gaskets.

Fig. 288: Removing Water By-Pass Joint FR
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
14.REMOVE W/CATALYST CONVERTER ASSY

Fig. 289: Removing Cylinder Head LH
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15.REMOVE CYLINDER HEAD LH
a. Disconnect the wire clamp from the wire bracket on the cylinder head cover.
b. Remove the EVAP from the cylinder head cover.
c. Remove the 9 bolts, 9 seal washers, c
ylinder head cover and gasket.

Fig. 290: Identifying Cylinder Head Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
d. Uniformly loosen and remove the 10 cylinder head bolts and plate washers in the sequence shown
in the illustration.
e. Remove the cylinder head together with the LH manifold.
16.REMOVE CYLINDER HEAD GASKET NO.2

Fig. 291: Removing Cylinder Head Gasket No.2
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
17.INSTALL CYLINDER HEAD GASKET NO.2
a. Place a new cylinder head gasket in position on the cylinder block.
b. The rear side of the cylinder head gasket has marks so that the RH and LH banks can be
distinguished. A "3L" mark is on the LH bank's gasket.
18.INSTALL CYLINDER HEAD LH
a. Check that the cut part of the crankshaft timing pulley is in the position shown in the illustration,
and that the piston is below the TDC of compression.
b. Install the cylinder head together with the manifold RH to the cylinder block.
c. Apply a light coat of engine oil on the threads and under the head of the cylinder head bolts.
d. Put the washer on the bolt, and insert the bolt with washer into the c
ylinder head.

Fig. 292: Identifying Cylinder Head LH
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

Fig. 293: Tightening Cylinder Head Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
e. Install and uniformly tighten the 10 cylinder head bolts, and plate washers in the sequence shown in
the illustration.
Torque: 59 N.m (602 kgf.cm, 44 ft.lbf)

Fig. 294: Installing Cylinder Head Cover
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
f. Mark the front of the cylinder head bolt head with paint.
g. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
h. Check that the painted mark is now at a 90° angle to the front.

Fig. 295: Identifying Painted Mark
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
i. Install the gasket to the cylinder head cover.
j. Install the seal washer to the bolt.
k. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque: 6.0 N.m (61 kgf.cm, 53 in..lbf)
l. Install the hose bracket of the EVAP to the cylinder head cover.
m. Install the wire clamp to the bracket on the cylinder head cover.
19.INSTALL W/CATALYST CONVERTER ASSY
20.INSTALL WATER BYPASS JOINT FR
a. Install 2 new gaskets and the water bypass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
b. Connect the ECT connector.

Fig. 296: Installing Water By-Pass Joint FR
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.