Lexus ES: Removal

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / 2gr-fks (intake / Exhaust) / Intake Manifold / Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during intake manifold removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
*: When performing learning using the Techstream. Click here
Battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane Control System (for Gasoline Model)
		Pre-collision System (for Gasoline Model)
		Parking Support Brake System (for Gasoline Model)*
		Lighting System (for Gasoline Model)
	Memorize steering angle neutral point	Parking Assist Monitor System (for Gasoline Model)
	Memorize steering angle neutral point	Panoramic View Monitor System (for Gasoline Model)
	Initialize power trunk lid system	Power Trunk Lid System (for Gasoline Model)
Replacement of port fuel injector assembly Replacement of fuel pressure sensor (fuel delivery pipe with sensor assembly) Replacement of throttle body with motor assembly Cleaning the deposits from the throttle body with motor assembly	Inspection after repair	Poor idle, etc. Engine start function, etc.

NOTICE:

After the engine switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) battery terminal. (for Audio and Visual System)
After the engine switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the engine switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) battery terminal. (for Navigation System)

PROCEDURE

1. PRECAUTION

NOTICE:

After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

2. DISCHARGE FUEL SYSTEM PRESSURE

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3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

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4. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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5. REMOVE FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

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6. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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7. REMOVE V-BANK COVER SUB-ASSEMBLY

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8. DISCONNECT VENTILATION HOSE

(a) Slide the clip and disconnect the ventilation hose from the intake air surge tank assembly.

9. DISCONNECT PURGE VALVE (PURGE VSV)

(a) Disconnect the No. 1 fuel vapor feed hose from the intake air surge tank assembly.

(b) Remove the bolt and disconnect the purge valve (purge VSV) from the intake air surge tank assembly.

10. REMOVE NO. 2 SURGE TANK STAY

(a) Remove the 2 bolts and No. 2 surge tank stay from the intake air surge tank assembly and camshaft housing RH.

11. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

(a) Disconnect the vacuum switching valve (for ACIS) connector.

(b) Disconnect the vacuum hose sub-assembly from the vacuum switching valve (for ACIS).

(d) Disengage the 2 clamps to disconnect the vacuum hose sub-assembly from the intake air surge tank assembly.

*1	Vacuum Hose Sub-assembly
*2	Vacuum Hose
*3	No. 2 Air Tube

(e) Disengage the clamp to disconnect the vacuum hose from the intake air surge tank assembly.

(f) Disengage the clamp to disconnect the No. 2 air tube from the intake air surge tank assembly.

(g) Remove the 5 bolts, 2 nuts and intake air surge tank assembly from the intake manifold.

	Bolt
	Nut

(h) Remove the plug from the intake air surge tank assembly.

12. REMOVE AIR SURGE TANK TO INTAKE MANIFOLD GASKET

(a) Remove the air surge tank to intake manifold gasket from the intake air surge tank assembly.

13. REMOVE NO. 1 V-BANK COVER BRACKET

HINT:

Perform this procedure only when replacement of the No. 1 V-bank cover bracket is necessary.

(a) Remove the 2 No. 1 V-bank cover brackets from the intake air surge tank assembly.

14. REMOVE NO. 2 ENGINE MOUNTING STAY RH

(a) Remove the 2 bolts.

(b) Disengage the wire harness clamp and disconnect the engine wire.

(d) Remove the bolt, 2 nuts and No. 2 engine mounting stay RH from the engine mounting insulator sub-assembly RH.

	Bolt
	Nut

(e) Remove the bolt and No. 2 engine mounting stay RH from the intake manifold and front No. 1 engine mounting bracket LH.

15. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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16. REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY

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17. REMOVE NO. 1 DELIVERY PIPE SPACER

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18. REMOVE INJECTOR VIBRATION INSULATOR

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19. REMOVE INTAKE MANIFOLD

(a) Remove the 4 bolts, 4 nuts and intake manifold from the cylinder head sub-assembly.

	Bolt
	Nut

20. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

(a) Remove the 2 No. 1 intake manifold to head gaskets from each cylinder head sub-assembly.

21. REMOVE STUD BOLT

HINT:

If a stud bolt is deformed or the threads are damaged, replace it.

(a) Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the intake manifold.

SEE MORE:

Reassembly

REASSEMBLY PROCEDURE 1. INSTALL LOWER POSITION INDICATOR HOUSING (a) Engage the 4 claws and 2 guides to install the lower position indicator housing to the shift lock control unit assembly. NOTICE: Do not damage the lower position indicator housing. 2. INSTALL SHIFT POSITION INDICATOR

Components

COMPONENTS ILLUSTRATION *A except 2GR-FKS - - *1 KICK DOOR CONTROL SENSOR *2 KICK DOOR CONTROL SENSOR WITH BRACKET *3 KICK DOOR CONTROL BRACKET - - ILLUSTRATION *A for 2GR-FKS - - *1 KICK DOOR CONTROL SENSOR *2 KICK DOOR CONTROL SENSOR WITH BRACKE

Lexus ES: Removal

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Installation

Intake System

Parts Location

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Reassembly

Components