Lexus GX470 2003-06

Intake Manifold

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine appearance cover
     
    Accelerator cable
     
    Throttle Position (TP) sensor connector
     
    Accelerator pedal position sensor
     
    Throttle motor connector
     
    Evaporative Emissions (EVAP) vacuum switching valve connector
     
    Fuel injector connectors
     
    Engine Coolant Temperature (ECT) sensor connector
     
    ETC gauge sender connector
     
    Heated Oxygen (HO2S) sensor connectors
     
    Fuel pressure regulator vacuum hose
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    EVAP hoses
     
    Power steering vacuum hoses
     
    Water bypass hose
     
    Engine control wiring harness clamps
     
    Cylinder head ground cables
     
    Intake manifold wire harness protector
     
    EVAP pipe
     
    Engine appearance cover brackets
     
    Intake manifold
     

  8.  

To install:

  1. Install or connect the following:

    Intake manifold. Tighten the fasteners to 13 ft. lbs. (18 Nm).
     
    Engine appearance cover brackets
     
    EVAP pipe
     
    Intake manifold wire harness protector
     
    Cylinder head ground cables
     
    Engine control wiring harness clamps
     
    Water bypass hose
     
    Power steering vacuum hoses
     
    EVAP hoses
     
    PCV valve and hose
     
    Fuel pressure regulator vacuum hose
     
    HO2S sensor connectors
     
    ETC gauge sender connector
     
    ECT sensor connector
     
    Fuel injector connectors
     
    EVAP vacuum switching valve connector
     
    Throttle motor connector
     
    Accelerator pedal position sensor
     
    TP sensor connector
     
    Accelerator cable
     
    Engine appearance cover
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  


    Click image to see an enlarged view

    Fig. Exploded of the intake manifold mounting




Click image to see an enlarged view

Fig. Intake manifold and related parts-2003-06 GX470 and LX470

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove the V bank cover.
  8.  
  9. Remove the timing belt.
  10.  
  11. Remove the camshaft pulleys.
  12.  
  13. Remove the camshaft position sensor.
  14.  
  15. Remove the power steering pump and set it aside with the lines still attached.
  16.  
  17. Remove the front exhaust pipe.
  18.  
  19. On models with an automatic transmission, remove the oil dipstick and tube.
  20.  
  21. Remove the ignition coils.
  22.  
  23. Remove the rear timing belt plates being careful not to drop anything.
  24.  
  25. Disconnect the fuel inlet hose.
  26.  
  27. Remove the intake manifold as follows:
    1. Disconnect the all electrical connectors from the manifold.
    2.  
    3. Disconnect all hoses from the intake manifold.
    4.  
    5. Disconnect the wire clamp bracket on the right hand delivery pipe.
    6.  
    7. Remove the engine wire harness protector from the water bypass joint and right hand cylinder head.
    8.  
    9. Remove the guide from the A/T bracket on the left side.
    10.  
    11. Remove the two ground cable from the left and right head.
    12.  
    13. Remove the bolts and disconnect the wire harness protector from the intake manifold.
    14.  
    15. Remove the engine wire from the engine hanger and bracket.
    16.  
    17. Remove the left and right side front V cover brackets.
    18.  
    19. Remove the nuts, bolts and manifold.
    20.  
    21. Remove the throttle body.
    22.  
    23. Remove the bolts and nuts that attach the upper manifold to the lower manifold.
    24.  
    25. Disconnect the EVAP hose from the upper manifold.
    26.  
    27. Remove the accelerator cable clamp and VSV for the EVAP.
    28.  
    29. Remove the bolt, union, gaskets and brake booster from the upper manifold.
    30.  
    31. Remove the EVAP pipe from the manifold.
    32.  
    33. Disconnect the fuel return hose from the regulator.
    34.  
    35. Remove the bolts attaching the fuel return hose to the lower manifold.
    36.  
    37. Remove the fuel pressure regulator, pulsation damper gaskets.
    38.  
    39. Remove the retainer and rear fuel pipe.
    40.  
    41. Remove the fuel rail and injectors.
    42.  

  28.  

To install:

  1. Install new intake manifold gaskets and the manifold. Tighten the bolts to 13 ft. lbs. (18 Nm) in several passes.
  2.  
  3. Install the throttle cover bracket, wire bracket and wire to the engine hanger bracket.
  4.  
  5. Install the wire to the timing belt rear plate.
  6.  
  7. Attach the wire protector to the intake manifold.
  8.  
  9. Attach the 2 ground cables the cylinder heads.
  10.  
  11. Connect the water bypass hoses to the throttle body.
  12.  
  13. Connect the wire clamps to the bracket on the right delivery pipe.
  14.  
  15. Attach the hoses to the intake manifold.
  16.  
  17. Attach the electrical connectors to the intake manifold.
  18.  
  19. Connect the fuel hose.
  20.  

 
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