INTAKE MANIFOLD INSTALLATION

INSTALL INTAKE AIR SURGE TANK ASSEMBLY
1. Install the union to check valve hose bracket with the bolt (for LHD).
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Install the V-bank cover bracket sub-assembly with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Install 2 new gaskets to the intake air surge tank assembly.
4. Temporarily install the intake air surge tank assembly with the 2 nuts and 8 bolts. Then tighten the 2 nuts and 8 bolts uniformly in the order shown in the illustration.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 16 ft.*lbf }
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
1. Apply gasoline to 8 new O-ring and install one to each injector.
  
  Note
  
  Check that there is no damage or foreign objects in the groove of the injector when installing the O-ring. If an injector falls out of the delivery pipe during removal or installation, reinstall the injector to the delivery pipe using a new O-ring between the injector and delivery pipe.
2. Install the injectors with delivery pipe assembly and 4 spacers with the 4 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 16 ft.*lbf }
3. Install the 2 wire harnesses with the 4 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
CONNECT NO. 3 FUEL HOSE
1. Push in the fuel tube connector to the No. 3 fuel hose until the fuel tube connector makes a "click" sound.
  Note
  
  Check that there is no damage or foreign objects on the fuel pipe connectors.
  
  After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
2. Install the 2 fuel pipe clamps.
CONNECT VACUUM HOSE ASSEMBLY (for LHD)
1. Connect the vacuum hose assembly to the intake air surge tank assembly with the clamp.
2. Connect the vacuum hose assembly to the hose clamp.
  
  Note
  
  Align the vacuum hose assembly matchmarks and the hose clamps as shown in the illustration.
CONNECT VACUUM HOSE ASSEMBLY (for RHD)
1. Connect the vacuum hose assembly to the intake air surge tank assembly with the clamp.
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
1. Install the water by-pass pipe to the intake air surge tank assembly with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the heater inlet water hose, heater outlet water hose, water inlet hose, water outlet hose, and water by-pass hose to the water by-pass pipe sub-assembly with the 5 clamps.
INSTALL INJECTOR DRIVER
1. Install the No. 2 V-bank cover bracket sub-assembly with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Install the 2 injector drivers with the 8 nuts.
  
  Torque:
  
  7.5 N*m { 76 kgf*cm, 66 in.*lbf }
3. Connect the 4 injector driver connectors to the injector driver.
  
  Tech Tips
  
  To connect the injector driver connectors, move the lock lever to lock the connector.
INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
1. Connect the ventilation hose.
2. Install the No. 1 vacuum switching valve assembly with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 16 ft.*lbf }
3. Connect the No. 2 fuel vapor feed hose to the No. 1 vacuum switching valve assembly.
4. Connect the fuel vapor feed hose to the intake air surge tank assembly.
CONNECT ENGINE WIRE (for LHD)
1. Connect the engine wire harness connector.
  
  Tech Tips
  
  To connect the injector driver connectors, move the lock lever to lock the connector.
  1. Connect the engine wire with the 4 nuts. (A)
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  2. Connect the 4 connectors and 5 clamps. (B)
  3. Install the ground cable with the bolt. (C)
    
    Torque:
    
    5.5 N*m { 56 kgf*cm, 49 in.*lbf }
  4. Connect the 4 injector driver connectors. (D)
  5. Install the wire harness with the nut to the relay box. (E)
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  6. Connect the 9 connectors and 3 clamps. (F)
  7. Install the harness with the nut to the +B terminal. (G)
    
    Torque:
    
    12 N*m { 122 kgf*cm, 9 ft.*lbf }
  8. Connect the generator connector and 2 clamps. (H)
  9. Install the oil cooler tube sub-assembly withe the bolt and nut. (I)
    
    Torque:
    
    Bolt
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
    
    Nut
    
    7.0 N*m { 71 kgf*cm, 62 in.*lbf }
  10. Connect the 2 connectors and then install the nut. (J)
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  11. Connect the starter connector. (K)
  12. Install the 2 bolts to the No. 3 exhaust manifold heat insulator. (L)
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
CONNECT ENGINE WIRE (for RHD)
1. Connect the engine wire harness connector.
  
  Tech Tips
  
  To connect the injector driver connectors, move the lock lever to lock the connector.
  1. Connect the engine wire with the 4 nuts. (A)
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  2. Connect the 4 connectors and 3 clamps. (B)
  3. Install the ground cable with the bolt. (C)
    
    Torque:
    
    5.5 N*m { 56 kgf*cm, 49 in.*lbf }
  4. Connect the 4 injector driver connectors. (D)
  5. Connect the 9 connectors and 3 clamps. (E)
  6. Install the harness with the nut to the +B terminal. (F)
    
    Torque:
    
    12 N*m { 122 kgf*cm, 9 ft.*lbf }
  7. Connect the generator connector and 2 clamps. (G)
  8. Install the oil cooler tube sub-assembly with the bolt and nut. (H)
    
    Torque:
    
    Bolt
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
    
    Nut
    
    7.0 N*m { 71 kgf*cm, 62 in.*lbf }
  9. Connect the 2 connectors and then install the nut. (I)
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  10. Connect the starter connector. (J)
  11. Install the 2 bolts to the No. 3 exhaust manifold heat insulator. (K)
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL OIL COOLER TUBE SUB-ASSEMBLY
1. Install the oil cooler tube sub-assembly with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL THROTTLE BODY ASSEMBLY
1. Connect the No. 4 water by-pass hose and No. 5 water by-pass hose to the throttle body assembly.
  
  Note
  
  Position the claws of the clamps as shown in the illustration.
2. Set the throttle body assembly and new gasket with the 2 stud bolts.
3. Using a "TORX" socket E6, tighten the 2 stud bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
4. Install the 2 bolts and 2 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
5. Connect the No. 4 water by-pass hose with the hose clamp.
6. Connect the No. 5 water by-pass hose with the hose clamp.
7. Connect the throttle body connector.
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
1. Install the air cleaner case sub-assembly with the 2 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
2. Connect the vacuum switching valve connector and clamp.
3. Connect the vacuum hose and 2 clamps.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
1. Install the air cleaner cap sub-assembly with air cleaner hose and lock the 2 clamps.
  
  Tech Tips
  
  Tightening torque for the hose clamp located between the air cleaner cap sub-assembly and air cleaner hose assembly is as follows.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
2. Connect the air cleaner hose to the throttle body with the hose clamp.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
3. Connect the 2 ventilation hoses with the 2 hose clamps.
4. Connect the mass air flow meter connector and wire harness clamp.
INSTALL NO. 1 AIR CLEANER INLET
1. Install the No. 1 air cleaner inlet with the bolt and clip.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
ADD ENGINE COOLANT
Note

Before adding coolant, turn the A/C switch OFF.

Total capacity

11.9 liters (12.6 US qts, 10.5 Imp. qts)
1. Tighten the radiator drain cock plug by hand.
2. Tighten the 2 cylinder block drain cock plugs.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
3. Add TOYOTA Super Long Life Coolant (SLLC) into the radiator reservoir.
  
  Capacity
  
  Approximately 5.0 liters (5.3 US qts, 4.4 Imp. qts)
  Tech Tips
  - LEXUS vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
  - Contact any authorized LEXUS dealer or repairer or another duly qualified and equipped professional for further details.
  - Thermostat opening timing can be confirmed by squeezing the inlet radiator hose and sensing vibrations when the coolant starts to flow inside the hose.
4. Further add coolant into the reservoir until it reaches the FULL line.
5. Squeeze the No. 1 and No. 2 radiator hoses several times, and then check the coolant level.
  
  If the coolant level is low, add coolant.
6. Using a 6 mm socket hexagon wrench, install the vent plug.
  
  Torque:
  
  1.5 N*m { 15 kgf*cm, 13 in.*lbf }
7. Bleed air from the cooling system.
  
  Note
  
  Before starting the engine, turn the A/C switch off.
  1. While idling the engine for approximately 10 minutes, make sure that the coolant remains at the FULL line by adding coolant as necessary.
  2. After idling the engine for 10 minutes, add coolant to the level shown in the illustration.
    
    Capacity
    
    Approximately 2.5 to 3.5 liters (2.6 to 3.7 US qts, 2.2 to 3.1 Imp.qts)
  3. Close the radiator reservoir cap, and run the engine at 1500 to 2000 rpm for 5 minutes.
    
    Tech Tips
    
    Thermostat opening timing can be confirmed by squeezing the No. 1 radiator hose and sensing vibrations when the SLLC starts to flow inside the hose.
    
    CAUTION:
    
    When squeezing the radiator hose:
    
    Wear protective gloves.
    
    Be careful as the radiator hose is hot.
    
    Keep your hands away from the radiator fan.
8. Stop the engine and wait until the coolant cools down to ambient temperature.
  
  CAUTION:
  
  Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot coolant and steam may be released and cause serious burns.
9. Check the coolant level.
  
  If the coolant level is below the FULL line, add coolant until it reaches the FULL line.
INSPECT FOR COOLANT LEAK
Note

Before performing each inspection, turn the A/C switch OFF.

CAUTION:

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
1. Fill the radiator with coolant and attach a radiator cap tester.
2. Warm up the engine.
3. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm², 17 psi), and check that the pressure does not drop.
  
  If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.
INSTALL ENGINE ROOM SIDE COVER RH (for LHD)
1. Install the engine room side cover RH with the 3 clips.
INSTALL ENGINE ROOM SIDE COVER RH (for RHD)
1. Install the engine room side cover RH with the 4 clips.
INSTALL ENGINE ROOM SIDE COVER LH (for LHD)
1. Install the engine room side cover LH with the 5 clips.
INSTALL ENGINE ROOM SIDE COVER LH (for RHD)
1. Install the engine room side cover LH with the 4 clips.
INSTALL COOL AIR INTAKE DUCT SEAL
1. Install the cool air intake duct seal with the 9 clips.
INSTALL NO. 1 ENGINE ROOM RELAY BLOCK COVER
1. Install the No. 1 engine room relay block cover.
INSTALL V-BANK COVER SUB-ASSEMBLY
1. Engage the 4 clips to install the V-bank cover sub-assembly.
  Note
  
  Be sure to engage the clips securely.
  
  Do not apply excessive force or hit the cover to engage the clips. This may cause the cover to break.
INSTALL NO. 2 ENGINE UNDER COVER
INSTALL REAR ENGINE UNDER COVER RH
INSTALL ENGINE UNDER COVER