2002 Lexus ES 300FACTORY OEM SERVICE PROCEDURE

Intake Air Control Valve Assembly: Replacement

  1. Drain coolant. See REPLACEMENT .
  2. Remove air cleaner cap with air cleaner hose. See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY .
  3. Remove front suspension upper brace center (w/front suspension brace upper center).
  4. Remove throttle body assembly. See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY .
  5. Remove intake air control valve assembly.
    1. Disconnect the vacuum hoses.
      Fig 1: Disconnecting Vacuum Hoses
      G01207197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt shown in the illustration. See Fig 2.
      Fig 2: Locating Intake Air Control Valve bolts
      G01207198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 bolts and the nut.
    4. Remove the intake air control valve.
    Fig 3: Locating Bolts For Removal
    G01207199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. Install intake air control valve assembly.
    1. Install a new gasket and the intake air control valve assembly.

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

      Fig 4: Installing Air Control Valve
      G01207200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt shown in the illustration.

      Torque:  20 N.m (199 kgf.cm, 14 ft.lbf)

      Fig 5: Installing Bolts
      G01207201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the vacuum hoses.
    Fig 6: Connecting Vacuum Hoses
    G01207202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. Install throttle body assembly. See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY .
  8. Install front suspension upper brace center (w/ front suspension brace upper center)

    Torque:  80 N.m (816 kgf.cm, 59 ft.lbf)

  9. Add coolant. See REPLACEMENT .
  10. Check engine coolant leak. See REPLACEMENT .
  11. Inspect function of throttle body assembly. See SFI SYSTEM .
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.