Lexus ES300 (1997 year). Manual — part 470

Z18575

8

6

5

4

3

2

1

9

10

7

11

S04791

8 mm Hexagon
Wrench

S04790

Chamber stay

EGR

Pipe

Engine

Hanger

–

ENGINE MECHANICAL

CYLINDER HEAD

EM–61

798

1997 LEXUS ES300 (RM511U)

28.

INSTALL INTAKE MANIFOLD ASSEMBLY

(a)

Install the intake manifold, delivery pipe and injectors as-
sembly with the 9 bolts, 2 plate washers and 2 nuts. Uni-
formly tighten the bolts and nuts, in several passes, in the
sequence shown.
Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)

(b)

Connect these hoses:

Fuel inlet hose to fuel filter

CAUTION:
Perform connecting operations of the fuel tube connector
(quick type) after observing the precautions.
(See page

SF–1

)

Heater hose to intake manifold

29.

RETIGHTEN WATER OUTLET MOUNTING BOLTS
AND NUTS

Tighten the 2 bolts and 2 nuts.

Torque: 15 N·m (150 kgf·cm, 11 ft·lbf)

30.

INSTALL AIR INTAKE CHAMBER ASSEMBLY

(a)

Using an 8 mm hexagon wrench, install a new gasket and
the air intake chamber assembly with the 2 bolts and 2
nuts. Uniformly tighten the bolts and nuts in several
passes.
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)

(b)

Install 2 new gaskets and No.2 EGR pipe with the 4 nuts.
Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

(c)

Install the No.1 engine hanger with the 2 bolts.
Torque: 39 N·m (400 kgf·cm, 19 ft·lbf)

(d)

Install the air intake chamber stay with the 2 bolts.
Torque: 19.5 N·m (200 kgf·cm, 14 ft·lbf)

(e)

Connect the hoses, cables, strap and clamp:

PCV hose to PCV valve on RH cylinder head

Ground strap and cable to intake air control valve
for ACIS
Connect the ground cable and strap with the nut.

Torque: 14.5 N·m (145 kgf·cm, 10 ft·lbf)

Ground cable to air intake chamber

Brake booster vacuum hose to air intake
chamber

2 water bypass hoses to throttle body

Air assist hose to throttle body

EVAP hose to pipe on emission control valve set

2 vacuum hoses to vacuum tank for ACIS

Engine wire clamp to emission control valve set

EM–62

–

ENGINE MECHANICAL

CYLINDER HEAD

799

1997 LEXUS ES300 (RM511U)

(f)

Install the PS pressure tube with the 2 nuts.

(g)

Connect these connectors and cables:

Throttle position sensor connector

IAC valve connector

EGR gas temperature sensor connector

EGR valve position sensor connector

VSV connector for ACIS

VSV connecter for EVAP

VSV connector for EGR

DLC1 to bracket on intake air control valve

Accelerator cable

A/T throttle cable

31.

INSTALL HIGH–TENSION CORD SET

32.

INSTALL V–BANK COVER

33.

INSTALL RH ENGINE MOUNTING STAY
(See page

EM–71

)

34.

INSTALL FRONT EXHAUST PIPE
(See page

EM–71

)

35.

INSTALL AIR FILTER AND AIR CLEANER CAP
ASSEMBLY

36.

FILL WITH ENGINE COOLANT

37.

START ENGINE AND CHECK FOR LEAKS

38.

VEHICLE ROAD TEST

Check for abnormal noise, shock, slippage, correct shift points
and smoothly operation.
39.

RECHECK ENGINE COOLANT LEVEL

40.

INSTALL RH FENDER APRON SEAL

EM048–02

S04767

Generator
Drive
Belt

RH Fender
Apron
Seal

No.2 Cooling Fan Connector

Upper Radiator Support

Upper Radiator
Support

No.1 Cooling
Fan Connector

No.1 ECT Switch
Wire Connector

Hood

Lower Radiator
Support

O–Ring

Lower Radiator
Support

PS Pump Drive
Belt

Hold Down
Clamp

Air Cleaner
Cap Assembly

Air Filter

Battery
Insulator

Air Cleaner Case

Battery

Actuator Cover

Battery
Tray

Accelerator
Cable

Cruise Control
Actuator Connector

Cruise Control Actuator

Gasket

LH Fender
Apron Seal

PS Pump

Radiator Lower
Hose

A/C Compressor
Connector

A/C Compressor

Generator Drive Belt
Adjusting
Bar Bracket

Washer
Hose for
Windshield

Drain Plug

EVAP Hose

MAF Meter
Connector

EGR Vacuum
Hose

A/T
Oil Cooler
Hose

Gasket

Gasket

Front Exhaust Pipe

Stay

Non–reusable part

62 (630, 46)

62 (630, 46)

56 (570, 41)

33 (330, 24)

25 (250, 18)

43 (440, 32)

N·m (kgf·cm, ft·lbf) : Specified torque

33 (330, 24)

Bracket

Radiator
Assembly

–

ENGINE MECHANICAL

ENGINE UNIT

EM–63

800

1997 LEXUS ES300 (RM511U)

ENGINE UNIT

COMPONENTS

S05518

Non–reusable part

80 (820, 59)

48 (490, 35)

64 (650, 47)

66 (670, 48)

64 (650, 47)

64 (650, 47)

32 (320, 23)

49 (500, 36)

294 (3,000, 217)

64 (650, 47)

127 (1,300, 94)

RH Drive Shaft

Tie Rod End

Engine Moving
Control Road

No.2 RH Engine
Mounting Bracket

Engine and Transaxle
Assembly

LH Drive Shaft

Lower Suspension Arm

RH Engine
Mounting Stay

Front Engine
Mounting Insulator

Rear Engine
Mounting
Insulator

Transaxle
Control Cable

Engine Mounting Absorber

N·m (kgf·cm, ft·lbf) : Specified torque

EM–64

–

ENGINE MECHANICAL

ENGINE UNIT

801

1997 LEXUS ES300 (RM511U)