ES300 1992-1997

Valve Covers

Print

Removal & Installation



Specific to:

Lexus ES300 1992-1994


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.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Disconnect the accelerator cable from throttle body.
  8.  
  9. Disconnect the throttle cable from throttle body.
  10.  
  11. Remove the air cleaner cap, air flow meter and air cleaner hose. Refer to Air Cleaner Removal & Installation.

    Click image to see an enlarged view

    Fig. Cylinder heads and related components

  12.  
  13. 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.  

  14.  
  15. 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.  

  16.  
  17. 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.  

  18.  
  19. 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.  

  20.  
  21. Remove the distributor.
  22.  
  23. 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.  

  24.  
  25. 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.  

  26.  
  27. 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.  

  28.  
  29. 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.  

  30.  
  31. 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.  

  32.  
  33. Disconnect hoses:
    1. Brake booster vacuum hose
    2.  
    3. PS air hose
    4.  
    5. PCV hose
    6.  
    7. EGR water bypass hose
    8.  

  34.  
  35. Disconnect the cold start injector connector.
  36.  
  37. 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.  

  38.  
  39. 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.  

  40.  
  41. Remove the No. 1 cooler. Remove the two nuts, bolt, No. 1 EGR cooler and gasket.
  42.  
  43. 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)
     

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

  44.  
  45. 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.  

  46.  
  47. Remove the air pipe:
    1. Disconnect the two air hoses from the intake manifold.
    2.  
    3. Remove the two bolts and air pipe.
    4.  

  48.  
  49. 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.
  50.  
  51. Remove the water bypass outlet. Remove the two nuts, water bypass outlet and gasket.
  52.  
  53. Remove intake manifold:
    1. 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.
    4.  

  54.  
  55. Remove spark plugs.
  56.  
  57. Remove the cylinder head covers. Remove the eight nuts, seal washers, cylinder head cover and gasket. Remove the two cylinder head covers.

    Click image to see an enlarged view

    Fig. Remove the cylinder head covers

  58.  

To install:

  1. Apply sealant to the cylinder heads as shown.

    Click image to see an enlarged view

    Fig. Cylinder head cover sealant application 1



    Click image to see an enlarged view

    Fig. Cylinder head cover sealant application 2

  2.  
  3. Install the gasket to the cylinder head cover.
  4.  
  5. Install the cylinder head covers with the seal washers and nuts. Tighten the nuts to 52 inch lbs. (6 Nm).
  6.  
  7. Installation is reverse of removal replacing gaskets as necessary.
  8.  

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. Cylinder heads and related components

  6.  
  7. Disconnect the accelerator cable.
  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 upper radiator hose.
  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 cylinder head rear plate.

    Click image to see an enlarged view

    Fig. Remove the cylinder head rear plate

  94.  
  95. Remove the water inlet pipe.
  96.  
  97. Remove the air assist hose and vacuum hose.
  98.  
  99. Remove the intake manifold and fuel rail assembly.
  100.  
  101. Remove the water outlet.
  102.  
  103. Remove the EGR pipe from the right exhaust manifold.
  104.  
  105. Remove the 6 bolts and 6 ignition coils from the RH and LH cylinder heads.
  106.  
  107. Remove spark plugs.
  108.  
  109. Remove the bolts, cylinder head covers and gaskets.

    Click image to see an enlarged view

    Fig. Remove the cylinder head covers-1995-97 models

  110.  

To install:

  1. Apply sealant to the cylinder heads as shown.

    Click image to see an enlarged view

    Fig. Right-hand cylinder head cover sealant application-1995-98 models



    Click image to see an enlarged view

    Fig. Left-hand cylinder head cover sealant application-1995-98 models

  2.  
  3. Install the gasket to the cylinder head cover.
  4.  
  5. Install the cylinder head covers and bolts. Tighten the bolts uniformly in several passes to 69 inch lbs. (8 Nm).
  6.  
  7. Installation is reverse of removal replacing gaskets as necessary.
  8.  

 
label.common.footer.alt.autozoneLogo