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Home >> Lexus >> 2023 >> ES 300h Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Intake / Exhaust System (A25A-FXS) - Service Information >> Intake Manifold >> Installation [06/2018 - 08/2021] >> Procedure

Installation [06/2018 - 08/2021]: Procedure

  1. INSTALL VACUUM HOSE 
    1. Install the vacuum hose to the intake manifold.
  2. INSTALL NO. 1 ENGINE COVER 
    1. Install the No. 1 engine cover with the clip.
  3. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
    1. Install a new No. 1 intake manifold to head gasket to the intake manifold.
  4. INSTALL INTAKE MANIFOLD 
    1. w/o Stud Bolt:
      1. Temporarily install the intake manifold to the cylinder head sub-assembly with the 5 bolts.
        Fig 1: Intake Manifold Bolt Tightening Sequence (w/o Stud Bolt) [06/2018 - 08/2021]
        GTY747938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Tighten the 5 bolts in the order shown in the illustration.

        Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

    2. w/ Stud Bolt:
      1. Temporarily install the intake manifold to the cylinder head sub-assembly.
        Fig 2: Intake Manifold Bolt Tightening Sequence (w/ Stud Bolt) [06/2018 - 08/2021]
        GTY944071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

        Torque: 6.5 N.m (66 kgf/cm, 58 in.lbf) 

      3. Temporarily install the 3 bolts and 2 nuts.
        Fig 3: Intake Manifold Nut & Bolt Tightening Sequence [06/2018 - 08/2021]
        GTY912987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Tighten the 3 bolts and 2 nuts in the order shown in the illustration.

        Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

  5. INSTALL NO. 2 FUEL VAPOR FEED HOSE 
    1. Install the No. 2 fuel vapor feed hose to the intake manifold.
  6. INSTALL NO. 2 WATER BY-PASS PIPE 
    1. Temporarily install the No. 2 water by-pass pipe to the cylinder block sub-assembly with the bolt (B).
      GTY742337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an 8 mm socket wrench, temporarily install the No. 2 water by-pass pipe to the intake manifold with the 2 bolts (A).
    3. Tighten the bolt (B).

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

    4. Using the 8 mm socket wrench, tighten the 2 bolts (A).

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

    5. Engage the wire harness clamp to connect the HV air conditioning wire.
  7. CONNECT NO. 3 WATER BY-PASS PIPE 
    1. Using an 8 mm socket wrench, connect the No. 3 water by-pass pipe to the intake manifold with the bolt.

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

    2. Connect the No. 5 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.
  8. CONNECT ENGINE WIRE 
    1. Engage the wire harness clamp to connect the engine wire to the intake manifold.
      GTY754168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt.

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

    3. Connect the engine wire to the cylinder head sub-assembly with the bolt.

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

      GTY763895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the No. 5 engine wire connector.
  9. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to INSTALLATION [06/2018 - ]

  10. INSTALL E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR) 

    Refer to PROCEDURE - Step 1

  11. INSTALL EGR VALVE ASSEMBLY 

    Refer to INSTALLATION [06/2018 - 08/2021]

  12. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to INSTALLATION [06/2018 - ]

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