2003 LEXUS LS430 Intake manifold

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
)

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.

Fig. 63: Installing Gaskets
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
b. Install the intake manifold assy with the 6 bolts and 4 nuts.
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
c. Connect the 8 in
jector connectors.

Fig. 64: Installing Intake Manifold Assy
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
d. Install the engine wire protector (rear side) with the 2 bolts.
e. Install the engine wire protector (LH side) with the 4 bolts.
f. Install the 2 wire clamps on the en
gine wire (RH side) to the brackets on the RH delivery pipe.

Fig. 65: Installing Engine Wire Protector (Rear Side)
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
g. Install the V-bank cover fastener with the bolt.
Torque: 7.5 N.m (77 kgf.cm, 66 in.lbf)
h. Install the V-bank cover bracket No. 1 with the bolt.
Torque: 7.5 N.m (77 kgf.cm, 66 in.lbf)
i. Connect the VSV connector for ACIS.
Fig. 66: Connecting VSV Connector For ACIS

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
j. Install the V-bank cover bracket No. 3 with the bolt.
Torque: 7.5 N.m (77 kgf.cm, 66 in.lbf)
k. Install the V-bank cover bracket No. 2 with the bolt.
Torque: 7.5 N.m (77 kgf.cm, 66 in.lbf)
l. Connect the VSV for EVAP to the intake manifold with the bolt.
Torque: 7.5 N.m (77 kgf.cm, 66 in.lbf)
m. Connect the EVAP hose to the VSV for EVAP.