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Installation [11/2021 - ]: Procedure

WARNING: This page is about a different car, the 2024 Lexus IS 500, 2023 Lexus IS 500, and 2022 Lexus IS 500. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 
    1. Install 2 new No. 1 intake manifold to head gaskets to the cylinder block sub-assembly.
    2. Temporarily install the intake air surge tank assembly to the cylinder block sub-assembly with the 8 bolts and 2 nuts.
    3. Tighten the 8 bolts and 2 nuts in the order shown in the illustration.
      Fig 1: Intake Air Surge Tank Assembly Tightening Sequence
      GTY510572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

    4. Connect the wire harness bracket to the intake air surge tank assembly with the bolt.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  2. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. Connect the No. 1 fuel pipe sub-assembly to the intake air surge tank assembly with the bolt.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  3. INSTALL NO. 2 V-BANK COVER BRACKET SUB-ASSEMBLY 
    1. Install the No. 2 V-bank cover bracket sub-assembly to the intake air surge tank assembly with the bolt.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  4. INSTALL V-BANK COVER BRACKET SUB-ASSEMBLY 
    1. Install the V-bank cover bracket sub-assembly to the intake air surge tank assembly with the bolt.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  5. INSTALL PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  6. INSTALL INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 2

  7. INSTALL NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 3

  8. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  9. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  10. INSTALL FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  11. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. Install the water by-pass pipe sub-assembly 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 water inlet hose to the water by-pass pipe sub-assembly and slide the clip to secure it.
      GTY514417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Heater Water Inlet Hose
      *2 Heater Water Outlet Hose
      *3 No. 3 Water By-pass Hose
      *4 Water By-pass Hose
      *5 No. 5 Water By-pass Hose
    3. Connect the heater water outlet hose to the water by-pass pipe sub-assembly and slide the clip to secure it.
    4. Connect the No. 5 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.
    5. Connect the water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.
    6. Connect the No. 3 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.
    7. Install the 2 water hose sets to the heater water inlet hose and heater water outlet hose.
  12. INSTALL INJECTOR DRIVER BRACKET 
    1. Install the 2 injector driver brackets to the intake air surge tank assembly with the 4 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  13. CONNECT VENTILATION HOSE 
    1. Connect the ventilation hose to the intake air surge tank assembly and slide the clip to secure it.
  14. INSTALL FUEL VAPOR FEED HOSE 
    1. Install the fuel vapor feed hose to the intake air surge tank assembly and slide the clip to secure it.
  15. CONNECT VACUUM HOSE SUB-ASSEMBLY 
    1. Connect the vacuum hose sub-assembly to the intake air surge tank assembly.
  16. CONNECT NO. 5 ENGINE WIRE 
    1. Engage the 4 clamps and connect the No. 5 engine wire to the intake air surge tank assembly.
  17. ENGAGE ENGINE WIRE 
    1. Engage the wire harness to the engine room ECU box.

      Refer to PROCEDURE - Step 4

    2. Connect the engine wire harness connector.
    3. Engage the claw and connect the engine wire harness.
    4. Connect the 7 connectors.
      GTY1084201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Connector
    5. Engage the 7 clamps.
    6. Install the 2 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

    7. Connect the 4 connectors.
      GTY510379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt (A)
      *b Bolt (B)
      Bolt
      Connector
    8. Engage the 2 clamps.
    9. Install the bolt (A) and (B).

      Bolt (A) 

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      Bolt (B) 

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

    10. Engage the fuel tube sub-assembly to the engine wire.
      GTY1084384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Nut
      Connector Fuel Tube Sub-assembly
    11. Connect the 12 connectors.
    12. Engage the 4 clamps.
    13. Install the 2 bolts and 4 nuts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  18. INSTALL ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 89

  19. INSTALL ENGINE ROOM ECU COVER 

    Refer to PROCEDURE - Step 5

  20. CONNECT UNION TO CHECK VALVE HOSE 
    1. Connect the union to check valve hose to the intake air surge tank assembly and slide the clip to secure it.
    2. Engage the union to check valve clamp.
  21. INSTALL INJECTOR DRIVER 

    Refer to PROCEDURE - Step 1

  22. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 1

  23. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to INSTALLATION [11/2021 - ]

  24. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [11/2021 - 09/2022] , or refer to INITIALIZATION [09/2022 - 10/2023] , or refer to INITIALIZATION [10/2023 - ]

  25. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 2

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