2003 LEXUS LS430 cylinder head

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. 10: Locating Mark
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4.INSTALL AIR CLEANER INLET NO.1
ADJUSTMENT
1.REMOVE V-BANK COVER
2.REMOVE CYLINDER HEAD COVER SUB-ASSY (See REPLACEMENT
)
3.REMOVE CYLINDER HEAD COVER SUB-ASSY LH (See REPLACEMENT
)
4.SET NO. 1 CYLINDER TO TDC/COMPRESSION
a. Turn the crankshaft damper, and align its groove with timing mark "0" of the timing belt No. 1
cover.

Fig. 18: Adjusting Shim Selection Chart (Exhaust)
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9.INSTALL NO.3 CAMSHAFT SUB-ASSY (See REPLACEMENT
)
10.INSTALL CAMSHAFT (See REPLACEMENT
)
11.INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See REPLACEMENT
)
12.INSTALL CYLINDER HEAD COVER SUB-ASSY (See REPLACEMENT
)
13.INSTALL V-BANK COVER
COMPONENTS

a. Check the steering wheel at the straight-ahead position.
b. Remove the 2 bolts and sliding yoke from the steering intermediate shaft.
Fig. 34: Removing Bolts And Sliding Yoke

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33.REMOVE FRONT DISC BRAKE CYLINDER ASSY RH (See OVERHAUL
)
34.REMOVE DISC BRAKE CYLINDER ASSY LH (See OVERHAUL
)
35.REMOVE FRONT SUSPENSION UPPER ARM ASSY RH (See REPLACEMENT
)
36.REMOVE FRONT SUSPENSION UPPER ARM ASSY LH (See REPLACEMENT
)
37.REMOVE PNEUMATIC FRONT RH W/ SHOCK ABSORBER CYLINDER ASSY (See
REPLACEMENT
)
38.REMOVE PNEUMATIC FRONT LH W/ SHOCK ABSORBER CYLINDER ASSY (See
REPLACEMENT
)
39.REMOVE HEIGHT CONTROL SENSOR LINK SUB-ASSY FRONT (See REPLACEMENT
)
40.REMOVE STABILIZER BRACKET FRONT (See REPLACEMENT
)
41.DISCONNECT POWER STEERING GEAR HOUSING ASSY
a. Remove the bolt, and disconnect the 2 PS oil tubes from the front frame.
b. Remove the 4 bolts, and disconnect the PS gear housing from the front frame.

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
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

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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

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. 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.