Manifold gasket LEXUS LS430 2003 Factory Repair Manual

HINT:
See COMPONENTS

1.REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO. 2
2.REMOVE INSTRUMENT PANEL GARNISH SUB-ASSY LH (See step 22 on REPLACEMENT
)
3.REMOVE INSTRUMENT PANEL FINISH PANEL (See step 26 on REPLACEMENT
)
4.REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSY NO. 1 (See step 16 on
REPLACEMENT
)
5.REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSY NO. 1 (See step 19 on
REPLACEMENT
)
6.REMOVE CONSOLE PANEL SUB-ASSY UPPER (See step 38 on REPLACEMENT
)
7.REMOVE CONSOLE UPPER REAR PANEL SUB-ASSY (See step 39 on REPLACEMENT
)
8.REMOVE CONSOLE BOX CARPET (See step 40 on REPLACEMENT
)
9.REMOVE REAR CONSOLE ARMREST ASSY (See step 41 on REPLACEMENT
)
10.REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See step 26 on
REPLACEMENT
)
11.REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER (See step 31 on
REPLACEMENT
)
12.REMOVE CONSOLE BOX (See step 42 on REPLACEMENT
)
13.SEPARATE OXYGEN SENSOR (See REPLACEMENT
)
14.REMOVE EXHAUST PIPE ASSY
a. Remove the 4 bolts, nuts and 2 gaskets from the exhaust manifold.
b. Remove the exhaust pipe assy.
15.REMOVE FRONT FLOOR HEAT INSULATOR NO. 1
a. Remove the 4 bolts and heat insulator No. 1.
16.REMOVE PROPELLER SHAFT HEAT INSULATOR
a. Remove the 2 bolts and heat insulator.
17.REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY
a. Using SST, loosen the adjusting nut until it can be turned by hand.
SST 09922-10010
HINT:
Use 2 of the same t
ype of SST.

Fig. 21: Blowing Air From Intake Manifold Side Of Engine
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
4.INSPECT FUEL TANK CAP ASSY
a. Visually check if cap and/or gasket are deformed or damaged.
If necessar
y, repair or replace the cap.

Fig. 22: Removing Bolts And Disconnecting Engine Wire Protector
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
k. Disconnect the 2 wire clamps on the engine wire (RH side) from the brackets on the RH delivery
pipe.
l. Remove the 2 bolts, and disconnect the engine wire protector (rear side) from the rear water bypass
joint and RH cylinder head.
m. Disconnect the 8 injector connectors.
Fig. 23: Identifying Bolts

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
n. Remove the 6 bolts, 4 nuts, the upper and lower intake manifolds assembly and 2 gaskets.
8.REMOVE KNOCK SENSOR

Fig. 26: Installing Intake Manifold Assy
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
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. 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.)

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. 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.

Fig. 54: Installing Mounting Bracket And Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
81.INSTALL WIRING HARNESS HEAT INSULATOR NO.2
82.INSTALL EXHAUST MANIFOLD SUB-ASSY LH
a. Place a new gasket on the cylinder head with the white mark facing the manifold side.

Fig. 56: Installing Exhaust Manifold
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
83.INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
84.INSTALL EXHAUST MANIFOLD SUB-ASSY RH
a. Place a new gasket on the cylinder head with the white mark facing the manifold side.

Fig. 62: Identifying Seal Packing
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
101.INSTALL GENERATOR ASSY (See REPLACEMENT
)
102.INSTALL STARTER ASSY (See REPLACEMENT
)
103.INSTALL INTAKE MANIFOLD ASSY
a. Place 2 new gaskets on the cylinder heads with the white mark facing outward.