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Home >> Lexus >> 2004 >> SC 430 >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Intake Air Control System >> Intake Manifold To Head Gasket No. 1 >> Replacement

Intake Manifold To Head Gasket No. 1: Replacement

  1. DRAIN ENGINE COOLANT (See  REPLACEMENT  ) 
  2. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT 
  3. REMOVE V-BANK COVER 
    1. Remove the V-bank cover by removing the 2 nuts.
  4. REMOVE INTAKE AIR CONNECTOR PIPE 
    1. Disconnect the air hose and ventilation hose No.1.
    2. Remove the intake air connector pipe by removing the bolt and hose clamp.
  5. REMOVE THROTTLE BODY ASSY (See  REPLACEMENT  ) 
  6. REMOVE V-BANK COVER BRACKET NO.1 
  7. REMOVE V-BANK COVER BRACKET NO.2 
  8. REMOVE V-BANK COVER BRACKET NO.3 
  9. REMOVE V-BANK COVER BRACKET NO.4 
  10. REMOVE VACUUM SWITCHING VALVE ASSY 
  11. SEPARATE FUEL PIPE SUB-ASSY NO.2 
    1. Using a union nut wrench 14, disconnect the fuel main hose.

      SST 09023-38400

    Fig 1: Disconnecting Fuel Main Hose Using Union Nut Wrench 14
    G00926788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE INTAKE MANIFOLD ASSY 
    1. Remove the installation bolts and the water bypass pipes No. 1 and No. 2.
    2. Disconnect the vacuum hose (for the brake booster).
    3. Disconnect the air hose (of the power steering).
    4. Disconnect the ventilation hose.
    5. Disconnect the connector (for the injector).
    6. Remove the intake manifold by taking off the 6 bolts and 4 nuts.
  13. REMOVE INTAKE MANIFOLD TO HEAD GASKET NO.1 
  14. INSTALL INTAKE MANIFOLD TO HEAD GASKET NO.1 
    1. Install a new gasket to the cylinder head, as shown in Fig 2 .
      NOTE: Face the white painted side upward. 
      2. Fig 2: Installing New Gasket To Cylinder Head
      G00926789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL INTAKE MANIFOLD ASSY 
    1. Install the intake manifold with the 6 bolts and 4 nuts.
    2. Connect the connector (for the injector).
    3. Disconnect the ventilation hose.
    4. Connect the air hose (for the power steering).
    5. Connect the vacuum hose (for the brake booster).
    6. Install the water bypass pipes No. 1 and No. 2 with the bolt.
  16. INSTALL FUEL PIPE SUB-ASSY NO. 2 
    1. Using a union nut wrench 14, install the fuel main hose.

      Torque: 35 N.m (355 kgf.cm, 26 in.lbf) 

      SST 09023-38400

      Fig 3: Installing Fuel Main Hose Using Union Nut Wrench 14
      G00926790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL VACUUM SWITCHING VALVE ASSY 

    Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

  18. INSTALL V-VANK COVER BRACKET NO. 4 

    Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

  19. INSTALL V-BANK COVER BRACKET NO. 3 

    Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

  20. INSTALL V-BANK COVER BRACKET NO. 2 

    Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

  21. INSTALL V-BANK COVER BRACKET NO. 1 

    Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) 

  22. INSTALL INTAKE AIR CONNECTOR PIPE 
    1. Install the intake air connector pipe with the bolt and the hose clamp.

      Torque: 

      • 4 N.m (40 kgf.cm, 35 in.lbf) for hose clamp 
      • 5 N.m (50 kgf.cm, 44 in.lbf) for bolt 
    2. Connect the air hose and the ventilation hose No.1 together.
  23. INSPECT FUEL PUMP OPERATION AND CHECK FOR FUEL LEAKS 
  24. INSTALL V-BANK COVER 

    Torque: 5 N.m (50 kgf.cm, 44 in.lbf) 

  25. REFILL ENGINE COOLANT (See  REPLACEMENT  ) 
  26. INSPECT CHECK FOR ENGINE COOLANT LEAKS (See  REPLACEMENT  ) 
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