ES300 1992-1997

Intake Manifold

Print

Precautions



Specific to:

Lexus ES300 1993-1997


CAUTION
On models with an air bag, wait at least 90 seconds from the time that the ignition switch is turned to the LOCK position and the battery is disconnected before performing any further work.

Removal & Installation



Specific to:

Lexus ES300 1992-1994

  1. Disconnect the negative battery cable.

    Click image to see an enlarged view

    Fig. Intake manifold and related components

  2.  
  3. Drain the engine coolant.
  4.  
  5. Disconnect the accelerator cable from throttle body.
  6.  
  7. For vehicles equipped with automatic transaxles, disconnect the throttle cable from throttle body.
  8.  
  9. Remove the air cleaner cap, air flow meter and air cleaner hose. Refer to Air Cleaner Removal & Installation.
  10.  
  11. Remove the front exhaust pipe:
    1. Loosen the two bolts, and disconnect the bracket.
    2.  
    3. Remove the two bolts and nuts holding the front exhaust pipe to the catalytic converter.
    4.  
    5. Remove the four nuts holding the front exhaust pipe to the exhaust manifolds.
    6.  
    7. Remove the front exhaust pipe and gaskets.

      Click image to see an enlarged view

      Fig. Remove the front exhaust pipe

    8.  

  12.  
  13. Remove the alternator.
  14.  
  15. Remove the V-bank cover:
    1. Using a 5 mm hexagon wrench, remove the two nuts and V-bank cover.

      Click image to see an enlarged view

      Fig. Remove the V-bank cover

    2.  

  16.  
  17. Remove the ISC/IAC valve:
    1. Disconnect the following hoses:

      PS idle-up air hose
       
      Water bypass hoses
       
      No. 5 air hose
       

    2.  
    3. Disconnect the ISC/IAC valve connector.
    4.  
    5. Remove the two bolts, ISC valve and gasket.

      Click image to see an enlarged view

      Fig. Remove the ISC valve

    6.  

  18.  
  19. Remove the throttle body:
    1. Disconnect the following hoses:

      Three BVSV vacuum hoses
       
      Four EGR vacuum hoses
       
      Water bypass hose
       

    2.  
    3. Disconnect the throttle position sensor connector.
    4.  
    5. Remove the two bolts, two nuts, throttle body and gasket.

      Click image to see an enlarged view

      Fig. Remove the throttle body

    6.  

  20.  
  21. Remove the EGR valve and vacuum modulator:
    1. California only: Disconnect the EGR gas temperature sensor connector.
    2.  
    3. Remove the two nuts, EGR valve, vacuum modulator and gasket.

      Click image to see an enlarged view

      Fig. Remove the EGR valve and vacuum modulator

    4.  

  22.  
  23. Remove the distributor.
  24.  
  25. Remove the EGR pipe:
    1. Loosen the union nut.
    2.  
    3. Remove the two bolts, EGR pipe and gasket.

      Click image to see an enlarged view

      Fig. Remove the EGR pipe

    4.  

  26.  
  27. Remove the emission control valve set:
    1. Disconnect the two vacuum hoses of the fuel pressure control VSV.
    2.  
    3. Disconnect the two vacuum hoses of the IACV VSV.
    4.  
    5. Disconnect the two VSV connectors.
    6.  
    7. Remove the two bolts and emission control valve set.
    8.  

  28.  
  29. Disconnect the left-hand engine wire harness:
    1. Disconnect the following connectors:

      Three injector connectors
       
      Cold start injector time switch connector
       
      Water temperature sensor connector
       
      Oxygen sensor connector
       
      Knock sensor connector
       

    2.  
    3. Remove the two bolts, and disconnect the three clamps and the left-hand engine wire.

      Click image to see an enlarged view

      Fig. Disconnect the left-hand engine wire harness

    4.  

  30.  
  31. Remove the cylinder head rear plate:
    1. Disconnect the two vacuum hoses from the vacuum tank.
    2.  
    3. Disconnect the vacuum hose from the air intake chamber.
    4.  
    5. Remove the bolt, nut and rear plate.

      Click image to see an enlarged view

      Fig. Remove the cylinder head rear plate

    6.  

  32.  
  33. Remove the water outlet:
    1. Disconnect the radiator upper hose.
    2.  
    3. Disconnect the coolant reservoir hose.
    4.  
    5. Remove the three nuts, water outlet and gasket.
    6.  

  34.  
  35. Disconnect hoses:
    1. Brake booster vacuum hose
    2.  
    3. PS air hose
    4.  
    5. PCV hose
    6.  
    7. EGR water bypass hose
    8.  

  36.  
  37. Disconnect the cold start injector connector.
  38.  
  39. Remove the No. 2 fuel pipe:
    1. Remove the union bolt and two gaskets, and disconnect the No. 2 fuel pipe from the cold start injector.
    2.  
    3. Disconnect the IACV vacuum hose.
    4.  
    5. Remove the two union bolts, four gaskets and No. 2 fuel pipe.
    6.  

  40.  
  41. Remove the air intake chamber:
    1. Remove the nut and disconnect the PS ACV.
    2.  
    3. Remove the two bolts and No. 1 engine hanger.
    4.  
    5. Remove the two bolts and air intake chamber stay.
    6.  
    7. Remove the bolt and disconnect the hydraulic pressure pipe.
    8.  
    9. Remove the nut and disconnect the two ground straps.
    10.  
    11. Using an 8 mm hexagon wrench, remove the two bolts, nuts, air intake chamber and gasket.

      Click image to see an enlarged view

      Fig. Remove the air intake chamber

    12.  

  42.  
  43. Remove the No. 1 cooler. Remove the two nuts, bolt, No. 1 EGR cooler and gasket.
  44.  
  45. Disconnect the right-hand engine wire harness:
    1. Disconnect the following connectors:

      Three injector connectors
       
      Water temp. sender gauge connector
       
      Oxygen sensor connector
       
      PS pump connector
       
      Oil pressure switch connector
       
      Engine oil level sensor connector
       
      A/C compressor connector
       
      Water temp. sensor connector (for hydraulic cooling fan)
       

    2.  
    3. Remove the two clamps, four bolts and engine wire harness.
    4.  

  46.  
  47. Remove the left-hand delivery pipe and injectors:
    1. Disconnect the fuel return hose from the No.1 fuel pipe (fuel inlet hose).
    2.  
    3. Remove the two bolts and left-hand delivery pipe together with three injectors.
    4.  

  48.  
  49. Remove the air pipe:
    1. Disconnect the two air hoses from the intake manifold.
    2.  
    3. Remove the two bolts and air pipe.
    4.  

  50.  
  51. Remove the right-hand delivery pipe and injectors. Remove the three bolts and right-hand delivery pipe together with the No. 1 fuel pipe and three injectors.
  52.  
  53. Remove the water bypass outlet. Remove the two nuts, water bypass outlet and gasket.
  54.  
  55. Remove intake manifold:
    1. Remove the two bolts and No. 2 idler pulley bracket stay and disconnect the ground strap.

      Click image to see an enlarged view

      Fig. Remove the two bolts and No. 2 idler pulley bracket stay and disconnect the ground strap

    2.  
    3. Remove the eight bolts, four nuts, intake manifold and gasket.

      Click image to see an enlarged view

      Fig. Remove the eight bolts, four nuts, intake manifold and gasket

    4.  

  56.  

To install:

  1. Install the intake manifold with new gaskets. Tighten the nuts and bolts to 13 ft. lbs. (18 Nm).
  2.  
  3. Install the No. 2 idler pulley bracket and tighten to 13 ft. lbs. (18 Nm).
  4.  
  5. Install a new gasket and the water bypass outlet with the two nuts and tighten to 74 inch lbs. (8 Nm).
  6.  
  7. Install the fuel injectors and the delivery pipes.
  8.  
  9. Install the air pipe with the two bolts and tighten to 73 inch lbs. (8 Nm).
  10.  
  11. Connect the two clamps, and install the engine wire harness with the four bolts.
  12.  
  13. Connect the following connectors:

    Three injector connectors
     
    Water temp. sender gauge connector
     
    Oxygen sensor connector
     
    PS pump connector
     
    Oil pressure switch connector
     
    Engine oil level sensor connector
     
    A/C compressor connector
     
    Water temp. sensor connector (for hydraulic cooling fan)
     

  14.  
  15. Install a new gasket and the No.1 EGR cooler with the bolt and two nuts and tighten to 13 ft. lbs. (18 Nm).
  16.  
  17. Install the air intake chamber with new gaskets and tighten the mounting bolts to 32 ft. lbs. (43 Nm).
    1. Connect the two ground straps with the nut and tighten to 9 ft. lbs. (13 Nm).
    2.  
    3. Connect the hydraulic pressure pipe with the bolt and tighten to 14 ft. lbs. (20 Nm).
    4.  
    5. Install the air intake chamber stay and tighten to 29 ft. lbs. (39 Nm).
    6.  
    7. Install the No. 1 engine hanger and tighten to 29 ft. lbs. (39 Nm).
    8.  
    9. Connect the PS ACV with the nut.
    10.  

  18.  
  19. Install the No. 2 fuel pipe with four new gaskets and the union boots and tighten to 25 ft. lbs. (34 Nm).
    1. Connect the IACV vacuum hose.
    2.  
    3. Connect the No. 2 fuel pipe with two new gaskets and the union bolt and tighten to 11 ft. lbs. (15 Nm).
    4.  

  20.  
  21. Connect the cold start injector connector.
  22.  
  23. Connect the following hoses:

    Brake booster vacuum hose
     
    PS air hose
     
    PCV hose
     
    EGR water bypass hose
     

  24.  
  25. Install a new gasket and the water outlet with the three bolts and tighten to 73 inch lbs. (8 Nm).
    1. Connect the coolant reservoir hose.
    2.  
    3. Connect the radiator upper hose.
    4.  

  26.  
  27. Replace the rear cylinder head plate and nut.
    1. Connect the vacuum hose to the air intake chamber.
    2.  
    3. Connect the two vacuum hoses to the vacuum tank.
    4.  

  28.  
  29. Connect the three clamps of the left-hand engine wire harness and install the wire harness with the two bolts.
  30.  
  31. Connect the following connectors:

    Three injector connectors
     
    Cold start injector time switch connector
     
    Water temperature sensor connector
     
    Oxygen sensor connector
     
    Knock sensor connector
     

  32.  
  33. Install the emission control valve set with the two bolts and tighten to 73 inch lbs. (8 Nm).
    1. Connect the two VSV connectors.
    2.  
    3. Connect the two vacuum hoses to the IACV VSV.
    4.  
    5. Connect the two vacuum hoses to the fuel pressure control VSV.
    6.  

  34.  
  35. Install the EGR pipe with a new gasket and sleeve ball, and tighten the mounting bolts to 13 ft. lbs. (18 Nm) and the nut to 58 ft. lbs. (77 Nm).
  36.  
  37. Install the distributor.
  38.  
  39. Install the EGR valve and vacuum modulator with a new gasket. Tighten the mounting bolts to 13 ft. lbs. (18 Nm). Install the vacuum pipe hoses.
    1. California only: Connect the EGR gas temperature sensor connector.
    2.  

  40.  
  41. Install the throttle body.
    1. Install a new gasket and the throttle body with the two bolts and two nuts and tighten to 9 ft. lbs. (13 Nm).
    2.  
    3. Connect the throttle position sensor connector.
    4.  
    5. Connect the following hoses:

      Three BVSV vacuum hoses
       
      Four EGR vacuum hoses
       
      Water bypass hose
       

    6.  

  42.  
  43. Install the ISC valve:
    1. Install a new gasket with the two bolts and tighten to 9 ft. lbs. (13 Nm).
    2.  
    3. Connect the ISC valve connector.
    4.  
    5. Connect the following connectors:

      PS idle-up air hose
       
      Water bypass hoses
       
      No. 5 air hose
       

    6.  

  44.  
  45. Using a 5 mm hexagon wrench, install the V-bank cover with the two nuts.
  46.  
  47. Install the alternator.
  48.  
  49. Connect front exhaust pipe:
    1. Place three new gaskets on the front pipe.
    2.  
    3. Install the front pipe with the two bolts and six nuts. Torque the nut:

      To manifold: 46 ft. lbs. (62 Nm)
       
      To converter: 32 ft. lbs. (43 Nm)
       

    4.  
    5. Connect the bracket with the two bolts.
    6.  

  50.  
  51. Connect the air clearance hose, and install the air cleaner cap and air flow meter with the four clips.
    1. Tighten the air cleaner hose clamp bolt.
    2.  
    3. Connect the air hoses.
    4.  
    5. Connect the coil cord clamp.
    6.  
    7. Connect the air flow meter connector.
    8.  

  52.  
  53. Install the accelerator cable and connect the throttle cable, if equipped with an automatic transaxle.
  54.  
  55. Refill coolant.
  56.  
  57. Connect the negative battery cable.
  58.  
  59. Run the engine and check for leaks.
  60.  
  61. Adjust the timing.
  62.  
  63. Perform road test.
  64.  
  65. Recheck the fluid levels.
  66.  

Specific to:

Lexus ES300 1995-1997


CAUTION
Fuel injection systems remain under pressure even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Relieve the fuel pressure.
  2.  
  3. Disconnect the negative battery cable. If the vehicle is equipped with an air bag, wait at least 90 seconds from the time the ignition switch is turned to the "LOCK" position and the negative battery cable is disconnected before starting work.
  4.  
  5. Drain the cooling system.

    Click image to see an enlarged view

    Fig. Intake manifold and related components

  6.  
  7. Disconnect the accelerator cable and the throttle cable on vehicles equipped with an automatic transaxle.
  8.  
  9. Remove the air cleaner cover, air flow meter and the air duct.
  10.  
  11. Remove the cruise control actuator and bracket, if equipped.
  12.  
  13. Disconnect the two engine ground straps.
  14.  
  15. Remove the right engine mounting support.
  16.  
  17. Disconnect the radiator hoses.
  18.  
  19. Disconnect the two heater hoses.
  20.  
  21. Disconnect and plug the fuel feed and return lines from the fuel rail assembly.
  22.  
  23. Disconnect and plug the pressure hose from the hydraulic motor.
  24.  
  25. Remove the V-bank cover.
  26.  
  27. Disconnect the fuel pressure control VSV.
  28.  
  29. Disconnect the fuel pressure regulator.
  30.  
  31. Disconnect the cylinder head rear plate.
  32.  
  33. Disconnect the intake air control valve VSV.
  34.  
  35. Disconnect the EGR vacuum modulator.
  36.  
  37. Disconnect the EGR valve.
  38.  
  39. Disconnect the intake air control valve.

    Click image to see an enlarged view

    Fig. Emission control valves

  40.  
  41. Disconnect the fuel pressure regulator.
  42.  
  43. Disconnect the EGR VSV.

    Click image to see an enlarged view

    Fig. VSV connectors

  44.  
  45. Remove the two nuts and the emission control valve set.

    Click image to see an enlarged view

    Fig. Remove the two nuts and the emission control valve set

  46.  
  47. Disconnect the brake booster vacuum hose.
  48.  
  49. Disconnect the PCV hose.
  50.  
  51. Disconnect the intake air control valve vacuum hose.
  52.  
  53. Remove the data link connector from the mounting bracket.
  54.  
  55. Remove the two ground straps from the intake chamber.
  56.  
  57. Remove the hydraulic motor pressure hose from the intake chamber.
  58.  
  59. Remove the right oxygen sensor connector from the P/S pressure tube.
  60.  
  61. Remove the two nuts and the P/S pressure tube from the intake chamber.
  62.  
  63. Disconnect the two P/S air hoses.
  64.  
  65. Remove the engine hanger and the intake chamber support.
  66.  
  67. Remove the EGR pipe and gaskets.
  68.  
  69. Disconnect the throttle position sensor connector.
  70.  
  71. Disconnect the IAC valve connector.
  72.  
  73. Disconnect the EGR gas temperature connector.
  74.  
  75. Disconnect the A/C idle up connector.
  76.  
  77. Disconnect the two vacuum hoses from the TVV.
  78.  
  79. Disconnect the vacuum hose from the cylinder head rear plate.
  80.  
  81. Disconnect the vacuum hose from the charcoal canister.
  82.  
  83. Disconnect the air assist hose and the two water bypass hoses.
  84.  
  85. Remove the air intake chamber.
  86.  
  87. Disconnect the left engine wire harness and position it out of the way.
  88.  
  89. Remove the wire harness from the rear of the engine.
  90.  
  91. Disconnect the right engine wire harness and position it out of the way.
  92.  
  93. Remove the ignition coils and the spark plugs.
  94.  
  95. Remove the timing belt.
  96.  
  97. Remove the camshaft pulleys and the timing belt rear cover.
  98.  
  99. Remove the cylinder head rear plate.

    Click image to see an enlarged view

    Fig. Remove the cylinder head rear plate

  100.  
  101. Remove the water inlet pipe.
  102.  
  103. Remove the air assist hose and vacuum hose.
  104.  
  105. Remove the intake manifold and fuel rail assembly:
    1. Remove the 2 bolts, 2 nuts, 2 plate washers and intake manifold together with the delivery pipes, and injectors.

      Click image to see an enlarged view

      Fig. Remove the intake manifold and fuel rail assembly

    2.  

  106.  

To install:

  1. Install the intake manifold and the fuel rail assembly. Torque the intake manifold nuts and bolts to 11 ft. lbs. (15 Nm).
  2.  
  3. Install the air assist hose and the two water bypass hoses.
  4.  
  5. Install the water inlet pipe and the cylinder head rear plate.
  6.  
  7. Install the timing belt rear cover and the camshaft pulleys.
  8.  
  9. Install the timing belt.
  10.  
  11. Install the spark plugs and the ignition coils.
  12.  
  13. Install the right engine wire harness.
  14.  
  15. Install the wire harness to the rear of the engine.
  16.  
  17. Install the left engine wire harness.
  18.  
  19. Install the air intake chamber.
  20.  
  21. Use new gaskets and install the EGR pipe.
  22.  
  23. Connect the two TVV vacuum hoses.
  24.  
  25. Connect the vacuum hose to the rear cylinder head plate.
  26.  
  27. Connect the charcoal canister vacuum hose.
  28.  
  29. Connect the throttle position sensor connector.
  30.  
  31. Connect the IAC valve connector.
  32.  
  33. Connect the EGR gas temperature connector.
  34.  
  35. Connect the A/C idle up connector.
  36.  
  37. Install the engine hanger and the intake chamber support.
  38.  
  39. Connect the two P/S air hoses.
  40.  
  41. Install the P/S pressure tube to the intake chamber.
  42.  
  43. Install the oxygen sensor connector to the pressure tube.
  44.  
  45. Install the two ground straps to the intake chamber.
  46.  
  47. Install the data link connector to the bracket.
  48.  
  49. Connect the power brake booster vacuum hose.
  50.  
  51. Connect the PCV hose.
  52.  
  53. Connect the IAC valve vacuum hose.
  54.  
  55. Install the emission control valve set and related vacuum hoses and connectors.
  56.  
  57. Install the V-bank cover.
  58.  
  59. Connect the pressure hose to the hydraulic motor.
  60.  
  61. Connect the fuel lines to the fuel rail assembly.
  62.  
  63. Connect the heater and radiator hoses.
  64.  
  65. Install the right engine mounting support.
  66.  
  67. Connect the two engine ground straps.
  68.  
  69. Install the cruise control actuator and bracket.
  70.  
  71. Install the air cleaner, air flow meter and air duct assembly.
  72.  
  73. Connect the accelerator cable and the throttle cable on vehicles equipped with an automatic transaxle.
  74.  
  75. Fill the cooling system to the proper level with coolant.
  76.  
  77. Connect the negative battery cable.
  78.  
  79. Start the engine and check for leaks. Bleed the air from the cooling system.
  80.  
  81. Adjust the ignition timing.
  82.  
  83. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation.
  84.  
  85. Recheck the coolant and engine oil levels.
  86.  

 
label.common.footer.alt.autozoneLogo