2003 LEXUS LS430 replacement

Fig. 135: Identifying Oil Pan Stud Bolt Diameter
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
56.INSTALL OIL PAN SUB-ASSY (See REPLACEMENT
)
57.INSTALL OIL PAN BAFFLE PLATE (See REPLACEMENT
)
58.INSTALL OIL PAN SUB-ASSY NO.2 (See REPLACEMENT
)
59.INSTALL WATER PUMP ASSY
a. Install a new gasket and water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the
bolts, stud bolts and nut in several passes.
Torque:
21 N.m (214 kgf.cm, 16 ft.lbf) for bolt
18 N.m (184 kgf.cm, 13 ft.lbf) for stud bolt and nut
HINT:
Use bolts that are 30 mm (1.18 in.) in len
gth.

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
87.INSTALL OIL FILLER CAP SUB-ASSY
88.INSTALL SPARK PLUG
REPLACEMENT
1.DISCONNECT BATTERY NEGATIVE TERMINAL
2.REMOVE AIR CLEANER INLET NO.1
3.DRAIN ENGINE COOLANT
4.REMOVE V-BANK COVER
5.REMOVE INTAKE AIR CONNECTOR PIPE
6.REMOVE ENGINE UNDER COVER NO.1
7.DISCONNECT RADIATOR HOSE NO.1
8.DISCONNECT RADIATOR HOSE NO.2
9.DISCONNECT OIL COOLER INLET TUBE NO.1
10.DISCONNECT OIL COOLER OUTLET TUBE NO.1
11.REMOVE AIR CLEANER ASSY
12.REMOVE RADIATOR ASSY (See REPLACEMENT

13.REMOVE FAN AND GENERATOR V BELT (See REPLACEMENT
)
14.REMOVE VANE PUMP ASSY
a. Remove the 2 bolts, nut and pump.
HINT:
Pump should be removed with the hoses connected and then hang with a rope or wire on the body's side.
15.REMOVE GENERATOR ASSY (See REPLACEMENT
)
16.DISCONNECT COMPRESSOR AND MAGNETIC CLUTCH
HINT:
The cooler compressor with the magnetic clutch should be removed with the low-pressure and high-
pressure hoses connected and then hang with a rope or wire on the body's side.
17.REMOVE TIMING CHAIN OR BELT COVER NO.2
a. Disconnect the 2 PS air hoses from the clamp on the cover.
b. Remove the cap nut, 3 bolts, cover and gasket.

Fig. 212: Installing Cover With Cap Nut And Bolts
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
40.INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the cooler compressor, stay and wire bracket with the 3 bolts and nut.
Torque:
49 N.m (500 kgf.cm, 36ft.lbf) for bolt
29 N.m (296 kgf.cm, 21 ft.lbf) for nut
41.INSTALL GENERATOR ASSY (See REPLACEMENT
)
42.INSTALL VANE PUMP ASSY
a. Install the pump with the 2 bolts and nut. Alternately tighten the bolts and nut.
Torque:
39.2 N.m (400 kgf.cm, 29 ft.lbf) for bolt
43.1 N.m (440 kgf.cm, 32 ft.lbf) for nut
43.INSTALL FAN AND GENERATOR V BELT (See REPLACEMENT
)
44.INSTALL RADIATOR ASSY (See REPLACEMENT
)
45.INSTALL AIR CLEANER ASSY
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)

46.INSTALL OIL COOLER OUTLET TUBE NO.1
47.INSTALL OIL COOLER INLET TUBE NO.
48.INSTALL AIR CLEANER INLET NO.1
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
49.INSTALL INTAKE AIR CONNECTOR PIPE
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
50.INSTALL V-BANK COVER
Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
51.REFILL ENGINE COOLANT (See REPLACEMENT
)
52.CHECK FOR ENGINE COOLANT LEAKS (See ON
-VEHICLE INSPECTION )
53.INSTALL ENGINE UNDER COVER NO.1
54.CONNECT BATTERY NEGATIVE TERMINAL
REPLACEMENT
1.REMOVE TIMING BELT (See REPLACEMENT
)
2.REMOVE CYLINDER HEAD COVER SUB-ASSY (See REPLACEMENT
)
3.PISTON & VALVE BREAK PREVENT WORK
a. Turn the crankshaft timing pulley counterclockwise by 45° and match the cut part with the
illustrated position.
HINT:
When the No. 1 cylinder is positioned at 45° BTDC, the valve and piston do not interfere with each other
even when the valve is fully open.

Fig. 241: Installing Camshaft Timing Pulley
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
13.INSTALL CAMSHAFT TIMING PULLEY
a. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
b. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "R" mark forward.
c. Hold the hexagon wrench head portion of the camshaft, and install the 4 pulley bolts.
Torque: 7.5 N.m (77 kgf.cm, 66 in..lbf)
14.INSTALL CYLINDER HEAD COVER SUB-ASSY (See REPLACEMENT
)
15.INSTALL TIMING BELT (See REPLACEMENT
)
REPLACEMENT
1.REMOVE TIMING BELT (See REPLACEMENT
)
2.REMOVE CYLINDER HEAD COVER SUB-ASSY LH (See REPLACEMENT
)

Fig. 271: Removing Upper And Lower Intake Manifold Assembly
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
13.INSTALL CAMSHAFT TIMING PULLEY SUB-ASSY LH
a. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
b. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "L" mark forward.
c. Hold the hexagon wrench head portion of the camshaft, and install the 4 pulley bolts.
Torque: 7.5 N.m (77 kgf.cm, 66 in..lbf)
14.INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See REPLACEMENT
)
15.INSTALL TIMING BELT (See REPLACEMENT
)
REPLACEMENT

1.WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See PRECAUTION )
2.REMOVE CAMSHAFT (See REPLACEMENT
)
3.REMOVE THROTTLE BODY ASSY (See REPLACEMENT
)
4.REMOVE V-BANK COVER BRACKET NO.1
5.REMOVE V-BANK COVER BRACKET NO.2
6.REMOVE V-BANK COVER BRACKET NO.3
7.REMOVE V-VANK COVER BRACKET NO.4
8.REMOVE VACUUM SWITCHING VALVE ASSY
9.DISCONNECT FUEL PIPE SUB-ASSY NO.2 (See REPLACEMENT
)
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-Pass Joint
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 assembl
y and 2 gaskets.

Fig. 285: Installing Upper And Lower Intake Manifolds Assembly
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
b. Install the upper and lower intake manifolds assembly with the 6 bolts and 4 nuts.
Torque: 18 N.m (184 kgf.cm, 13 ft.lbf)
24.INSTALL FUEL PIPE SUB-ASSY NO.2 (See REPLACEMENT
)
25.INSTALL VACUUM SWITCHING VALVE ASSY
26.INSTALL V-VANK COVER BRACKET NO.4
27.INSTALL V-BANK COVER BRACKET NO.3
28.INSTALL V-BANK COVER BRACKET NO.2
29.INSTALL V-BANK COVER BRACKET NO.1
30.INSTALL THROTTLE BODY ASSY (See REPLACEMENT
)
31.INSTALL CAMSHAFT (See REPLACEMENT
)