2003 LEXUS LS430 Intake manifold

block and the manifolds for warpage.
MAXIMUM WARPAGE:
CYLINDER BLOCK CONTACTING SURFACE SPECIFICATIONS
If the warpage is greater than the maximum, replace the cylinder head.
Fig. 321: Inspecting Cylinder Head For Cracks

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
c. Inspect the cylinder head for cracks.
1. Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder
block surface for cracks.
If cracked, replace the c
ylinder head.
ItemSpecified Condition
Cylinder block surface0.05 mm (0.0020 in.)
Intake manifold surface0.10 mm (0.0039 in.)
Exhaust manifold surface0.10 mm (0.0039 in.)

Fig. 7: Installing O-Ring With Spindle Oil Or Gasoline
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
d. Install the injector to the delivery pipe and the lower intake manifold as shown in the illustration.
Before installing the injector, apply spindle oil or gasoline on the place where the delivery pipe or
intake manifold touches O-ring of the injector.

Fig. 8: Installing Injector To Delivery Pipe And Lower Intake Manifold
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
e. Observe these precautions when disconnecting the fuel tube connector (quick type):
1. Disen
gage the lock claw by lifting up the cover, as shown in the illustration.

b. Remove the 2 bolts.
c. Remove the fuel delivery pipe No. 2 by pulling it straight upward holding both the ends.
15.REMOVE FUEL INJECTOR ASSY
a. Remove the injector from the intake manifold.
b. Remove the O-ring, grommet and vibration insulator from the injector.
Fig. 32: Installing O
-Ring, Grommet And Vibration Insulator From Injector
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
16.INSTALL FUEL INJECTOR ASSY
a. Install a new grommet and vibration insulator to the injector.
b. Check the injector's grooves (where O-rings are installed) for foreign matter or damage. Apply

gasoline to 2 new O-rings and install them to the injector's grooves.
c. To install the fuel injector into the fuel delivery pipe, push the fuel injector while twisting it back
and forth. Install the 4 injectors.
d. Check that the injector can rotate smoothly.
17.INSTALL FUEL DELIVERY PIPE SUB-ASSY NO.2
a. Install the injector (with delivery pipe) to the intake manifold.
b. Under the above condition, turn the injector both ways by approximately 45 degrees.
c. Inserting a spacer in between, install the delivery pipe (with injector) with the 2 nuts.
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
18.INSTALL FUEL DELIVERY PIPE SUB-ASSY
a. Install the injector (with delivery pipe) to the intake manifold.
b. Under the above condition, turn the injector both ways by approximately 45 degrees.
c. Inserting a spacer in between, install the delivery pipe (with injector) with the 2 nuts.
Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
19.INSTALL FUEL PRESSURE PULSATION DAMPER ASSY
a. Inserting 2 new gaskets in between, install the fuel main hose to the fuel pressure pulsation damper.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

Fig. 9: Disconnecting Fuel Pipe Sub-Assy No. 2
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
13.REMOVE INTAKE MANIFOLD
a. Remove the bolt and the water by-pass pipe No. 1 and No. 2.
b. Disconnect the vacuum hose for the brake booster.
c. Disconnect the air hose for the power steering.
d. Disconnect the ventilation hose.
e. Disconnect the injector connector.
f. Remove the 6 bolts, 4 nuts and intake manifold.
14.REMOVE INTAKE MANIFOLD TO HEAD GASKET NO. 1
15.INSTALL INTAKE MANIFOLD TO HEAD GASKET NO. 1
a. Install 2 new gaskets to the cylinder head.
HINT:
The white-painted area on each gasket should face up as shown in the illustration.

Fig. 10: Installing Intake Manifold To Head Gasket No. 1
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
16.INSTALL INTAKE MANIFOLD
a. Install the intake manifold with the 6 bolts and 4 nuts.
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
b. Connect the injector connector.
c. Connect the ventilation hose.
d. Connect the air hose for the power steering.
e. Connect the vacuum hose for the brake booster.
f. Install the water by-pass pipe No. 1 and No. 2 with the bolt.
17.CONNECT FUEL PIPE SUB-ASSY NO. 2
a. Using SST, install the fuel main hose.
SST 09023-38401