Engine Mechanical: Other Lexus ES XV30

VALVE CLEARANCE

Note. Adjust valve clearance with engine cold.

1. Disconnect negative battery cable. Remove front upper suspension brace. Drain cooling system. Remove right fender apron seal. Using 5-mm hexagon wrench, remove 3 cap nuts and remove "V" bank cover.
2. Disconnect necessary hoses and electrical connections from vacuum switching valves. Disconnect necessary electrical connections, coolant hoses and vacuum hoses for removal of air intake chamber. (Scheme 30)
3. Remove bolts, nuts, air intake chamber and gasket. (Scheme 30) Disconnect electrical connectors for removal of wiring assemblies located above valve covers. Remove bolts and wiring assemblies.
4. Remove bolts and ignition coil assemblies. Mark ignition coil installation location for reassembly reference. Remove bolts, valve covers and gaskets. Disconnect upper radiator hose. Rotate crankshaft clockwise (viewed from front of engine) so cylinder No. 1 is at TDC on compression stroke. Cylinder No. 1 is front cylinder on right side when viewed from rear of engine. (Scheme 21)
5. Ensure timing mark on crankshaft pulley aligns with "0" mark on No. 1 timing belt cover. If timing marks are not aligned, rotate crankshaft clockwise one complete revolution. Ensure intake and exhaust lifters are loose on cylinder No. 1. NOTE: Valve clearances are checked with engine cold.
6. Using feeler gauge, measure and record valve clearance on intake valves of cylinders No. 1 and 6 and exhaust valves on cylinders No. 2 and 3. See step 1) in illustration. (Scheme 21)
7. Rotate crankshaft clockwise 2/3 turn (240 degrees). Measure and record valve clearance on intake valves of cylinders No. 2 and 3 and exhaust valves on cylinders No. 4 and 5. See step 2) in illustration. (Scheme 21)
8. Rotate crankshaft clockwise an additional 2/3 turn (240 degrees). Measure and record valve clearance on intake valves of cylinders No. 4 and 5 and exhaust valves on cylinders No. 1 and 6. Perform step 3) in illustration. (Scheme 21) Ensure valve clearance is within specification. See «VALVE CLEARANCE SPECIFICATIONS»(ref-159137-S02899351342003111300000) table. VALVE CLEARANCE SPECIFICATIONS (1) Application In. (mm) Exhaust Valve.010-.014 (.25-.35) Intake Valve.006-.010 (.15-.25) (1) Adjust valve clearance with engine cold.
9. If valve clearance requires adjustment, rotate camshaft so lobe on valve to be adjusted faces upward, away from valve lifter. Position notch on valve lifter perpendicular to camshaft. Ensure notch is not aligned with camshaft.
10. Using Valve Clearance Adjuster Set (SST 09248-55040), remove adjusting shim. Using SST "A", push downward on valve lifter. (Scheme 22)
11. Place SST "B" between camshaft and valve lifter with side marked with a "7" or "9" in right location, depending on cylinder application. (Scheme 22) Side marked with "7" should be used on front valves on cylinders No. 1 and 2. Remove SST "A".
12. Using small screwdriver and magnet, remove adjusting shim. Measure and record thickness of removed adjusting shim. Using measured clearance and adjusting shim thickness, select proper replacement adjusting shim. See «CALCULATING VALVE CLEARANCE»(ref-159137-S21868534612004050600000) table. Also (Scheme 23)or (Scheme 24). CALCULATING VALVE CLEARANCE Specification (1) (2) Application "A" Thickness Of New Shim "B" Thickness Of Used Shim "C" Measured Valve Clearance (1) Intake "A" = "B" + ("C" -.008 in. (.20 mm) (2) Exhaust "A" = "B" + ("C" -.012 in. (.30 mm)
13. Install replacement adjusting shim with imprinted number on adjusting shim facing valve lifter. Recheck valve clearance. Before installing valve cover and gasket, apply sealant at front and rear areas of cylinder head. (Scheme 25)
14. Using NEW gasket, install valve cover. Install and tighten valve cover bolts to specification in several steps. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000). To install remaining components, reverse removal procedure using NEW gaskets. Tighten all fasteners to specification. Fill cooling system and adjust control cables.

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

FUEL PRESSURE RELEASE

Ensure ignition is off. Remove circuit opening relay from fuse/relay box. (Scheme 32) Fuse/relay box is located at driver's side front corner of engine compartment. Start engine and run until it stops, then turn ignition off. Place a container under high-pressure fuel line connection. Slowly loosen and disconnect connection. Plug open end of fuel line. Reconnect fuel pump connector. Once fuel pressure is released, fuel system components may be serviced.

Scheme 32

Refer to these figures throughout procedure. (Scheme 26)- (Scheme 31).

Note. Remove engine and transaxle as an assembly.

CYLINDER HEAD & MANIFOLDS

Refer to these figures throughout procedure. (Scheme 26)- (Scheme 31).

CAMSHAFT

Note. When servicing camshafts, reference to right and left components are as viewed from rear of engine.

Refer to these figures throughout procedure. (Scheme 26)- (Scheme 31).

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159137-S34736421792003111300000). Disconnect negative battery cable. Remove suspension upper brace. Remove right front wheel and fender apron seal. Drain cooling system. Remove air cleaner cap assembly and air filter. Remove engine moving control rod and right engine mount stay.
2. Using 5-mm hexagon wrench remove 3 cap nuts from "V" bank cover and remove "V" bank cover. Remove air cleaner cap and airflow meter with air cleaner hose. Disconnect necessary electrical connections, ground straps, coolant hoses, fuel lines and vacuum hoses for removal of air intake chamber.
3. Remove nuts and air intake chamber located above intake manifold. (Scheme 30) Disconnect fuel injector connectors. Disconnect fuel inlet hose from fuel filter. Disconnect heater hose from intake manifold. Remove bolts, nuts and washer from intake manifold and remove intake manifold, fuel pipes and fuel injectors as an assembly. CAUTION: DO NOT allow injectors to fall from delivery pipe when removing from intake manifold.
4. Remove ignition coils. Remove timing belt, camshaft sprockets and No. 2 idler pulley. See «TIMING BELT REPLACEMENT - 3.0L V6»(ref-156551). Disconnect 3 engine wire clamps from timing belt cover. Remove 6 bolts and No. 3 timing belt cover.
5. Remove 6 injector connectors. Disconnect fuel inlet hose from fuel filter. Disconnect heater hose from intake manifold. Remove 9 bolts, 2 nuts and 2 plate washers. Remove intake manifold, delivery pipes and injectors assembly.
6. Disconnect wiring connectors and hoses from water outlet housing. Remove 2 bolts, 2 nuts and 2 plate washers and remove water outlet housing.
7. Remove generator bracket No. 2. Remove 9 bolts, cylinder head cover and gasket. see scheme 15 Remove 2 cylinder head covers.
8. To remove right-side camshafts, align timing marks (2 dots) on camshaft gears by rotating intake camshaft using hexagonal area of camshaft. To remove left camshafts, align timing marks (1 dot) on camshaft gears by rotating intake camshaft using hexagonal area of camshaft. see scheme 20
9. On exhaust camshafts, secure sub-gear on exhaust camshaft to main gear with 6 x 1.0 x 20 mm service bolt "A". see scheme 21 Before removing camshaft bearing cap bolts, ensure torsional spring force of sub-gear is held by service bolt "A".
10. Remove intake camshaft bearing cap bolts in sequence using several steps. see scheme 24 Remove camshaft bearing caps and intake camshaft. CAUTION: Camshaft bearing cap bolts must be removed in proper sequence to prevent damage to cylinder head and camshaft thrust surfaces.
11. Remove exhaust camshaft bearing cap bolts in sequence using several steps. see scheme 24 Remove camshaft bearing caps, exhaust camshaft and oil seal.
12. If disassembling exhaust camshaft gear, mount hexagonal area of camshaft in soft-jaw vise. Using Spanner Wrench (SST 09960-10010), rotate sub-gear counterclockwise and remove service bolt "A". see scheme 22 Remove snap ring, wave washer, sub-gear and gear spring. see scheme 23

Cylinder Head

1. Inspect cylinder head warpage at cylinder block and manifold surfaces. Replace cylinder head if warpage exceeds specification. See «CYLINDER HEAD»(ref-159137-S37468962562003111300000) table under ENGINE SPECIFICATIONS.
2. Using Plastigage, check camshaft oil clearance. Install camshaft in cylinder head. Tighten camshaft bearing caps using proper tightening sequence. see scheme 28
3. Replace camshaft and/or cylinder head if oil clearance is not within specification. See «CAMSHAFT»(ref-159137-S28038154422003111300000) table under ENGINE SPECIFICATIONS.
4. Check camshaft end play with camshaft bearing cap bolts tightened to specification. Replace camshaft and/or cylinder head if end play is not within specification. See «CAMSHAFT»(ref-159137-S28038154422003111300000) table under ENGINE SPECIFICATIONS.
5. Ensure valve lifter bore diameter is within specification. See «VALVE LIFTERS»(ref-159137-S40273616772003111300000) table under ENGINE SPECIFICATIONS.
6. If installing spark plug tubes in new cylinder head, apply sealant on cylinder head end of spark plug tube. Using press, install spark plug tube until distance between top surface of spark plug tube and camshaft bearing cap surface of cylinder head is 1.669-1.709 in. (42.40-43.40 mm).
7. If installing PCV pipe in new cylinder head, use hammer and wooden block. PCV pipes are installed between exhaust camshaft and outer edge of cylinder head. Install PCV pipe until top of pipe is even with valve cover gasket surface on cylinder head.

Valve Springs

Ensure valve spring free length, pressure and out-of-square are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals

Intake valve stem oil seal is Light Brown, and exhaust valve stem oil seal is Gray. Lubricate valve stem oil seal with engine oil. Install valve stem oil seal using Oil Seal Installer (SST 09201-41020).

Valve Guides

1. Ensure valve guide inside diameter is within specification. See «CYLINDER HEAD»(ref-159137-S37468962562003111300000) table under ENGINE SPECIFICATIONS. Replace valve guide if inside diameter exceeds specification.
2. To replace valve guide, heat cylinder head to 176-212°F (80-100°C). Using hammer and Valve Guide Remover/Installer (SST 09201-01055), drive valve guide from camshaft side of cylinder head.
3. Measure cylinder head valve guide bore inside diameter. If bore inside diameter is .4053-.4060 in. (10.295-10.312 mm), use standard valve guide. If bore inside diameter is .4073-.4080 in. (10.345-10.363 mm), use oversize valve guide.
4. If bore inside diameter exceeds .4060 in. (10.313 mm), machine valve guide bore to .4073-.4080 in. (10.345-10.363 mm) for oversize valve guide. If bore I.D. exceeds .4080 in. (10.363 mm), replace cylinder head. CAUTION: Exhaust valve guide is 1.594 in. (40.50 mm) long and intake valve guide is 1.358 in. (34.49 mm) long. Ensure proper length valve guide is installed.
5. To install valve guide, heat cylinder head to 176-212°F (80-100°C). Using hammer and valve guide remover/installer, drive valve guide in from camshaft side of cylinder head until valve guide installed height is within specification. See «CYLINDER HEAD»(ref-159137-S37468962562003111300000) table under ENGINE SPECIFICATIONS. Valve guide installed height is measured from top of valve guide to cylinder head surface, right next to valve guide.
6. Using .216 in. (5.48 mm) reamer, ream valve guide to obtain specified valve stem-to-guide oil clearance. See «CYLINDER HEAD»(ref-159137-S37468962562003111300000) table under ENGINE SPECIFICATIONS.

Valve Seat

Ensure valve seat angle and seat width are within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valve seat replacement information is not available from manufacturer.

Valves

Ensure minimum refinish length, stem diameter and valve margin are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. Replace valve if not within specification.

Valve Seat Correction Angles

Use 30 degree and 45 degree stones to lower valve seat contact area. Use 75 degree and 45 degree stones to raise valve seat contact area.

Valve Lifters

Ensure valve lifter diameter, bore diameter and oil clearance are within specification. See VALVE LIFTERS table under ENGINE SPECIFICATIONS. Replace components if not within specification.

Using "V" blocks and dial indicator, check camshaft runout. Ensure camshaft journal diameter and out-of-round are within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS. Replace camshaft if not within specification.

Piston & Rod

1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly reference. Piston and connecting rod must be installed in cylinder block with front mark on piston facing timing belt end of engine. (Scheme 33)
2. Before disassembling piston and connecting rod, try to move piston back and forth on piston pin. Replace piston and piston pin if any movement is felt.
3. When removing piston from connecting rod, remove snap rings from piston. Heat piston to 140°F (60°C) in water. Remove piston pin using a brass drift and plastic-face hammer. Separate piston from connecting rod. Ensure piston pin diameter is within specification. See «PISTONS, PINS & RINGS»(ref-159137-S25857494572003111300000) table under ENGINE SPECIFICATIONS.
4. Ensure connecting rod piston pin bushing bore diameter, crankpin bore diameter, bend and twist are within specification. See «CONNECTING RODS»(ref-159137-S05575642342003111300000) table under ENGINE SPECIFICATIONS. NOTE: Crankpin bore diameter is identified by size mark ("1", "2", "3" or "4") stamped on connecting rod. (Scheme 35)
5. Piston pin bushing can be replaced in connecting rod if bore diameter is not within specification. Use Bushing Remover/Installer (SST 09222-30010) and press to replace bushing.
6. Ensure bushing oil hole aligns with connecting rod oil hole. Hone bushing to obtain correct piston pin-to-rod clearance. See «PISTONS, PINS & RINGS»(ref-159137-S25857494572003111300000) table under ENGINE SPECIFICATIONS.
7. Use caliper to measure outside diameter of connecting rod bolt, just above threads. Replace connecting rod bolt if outside diameter is less than.276 in. (7.01 mm).
8. To reassemble, install piston on connecting rod with front mark on top of piston aligned with front mark on connecting rod. (Scheme 33) Install NEW snap ring in piston. Ensure ends of snap ring are not aligned with piston pin cutout area of piston. NOTE: With piston at 140°F (60°C), piston pin should be able to be pressed into piston using thumb pressure.
9. Heat piston to 140°F (60°C) in water. Coat piston pin with engine oil. Install piston pin and remaining NEW snap ring. Ensure ends of snap ring are not aligned with piston pin cutout area of piston.

Scheme 33

Fitting Pistons

1. To determine piston-to-cylinder clearance, measure piston skirt diameter at .913 in. (23.20 mm) from top of piston at 90 degree angle to piston pin.
2. Ensure piston diameter is within specification. See «PISTONS, PINS & RINGS»(ref-159137-S25857494572003111300000) table under ENGINE SPECIFICATIONS.
3. Measure cylinder bore diameter at .39 in. (10.0 mm) from top and bottom of cylinder bore and at middle of cylinder bore. Ensure cylinder bore diameter is within specification. See «CYLINDER BLOCK»(ref-159137-S12609165022003111300000) table under ENGINE SPECIFICATIONS.
4. Determine piston-to-cylinder clearance. Replace piston or cylinder block if clearance is not within specification. See «PISTONS, PINS & RINGS»(ref-159137-S25857494572003111300000) table under ENGINE SPECIFICATIONS.

Piston Rings

Ensure piston ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Position piston rings with ring end gaps in proper areas with identification mark on piston ring toward top of piston. (Scheme 34)

Note. No. 1 compression ring may contain a 1R or "T" identification mark and No. 2 compression ring may contain a 2R or 2T identification mark. Ensure proper ring is installed in correct location.

Scheme 34

Rod Bearings

1. Ensure connecting rod and connecting rod cap are marked with matching cylinder number for reassembly reference. Piston and connecting rod must be installed in cylinder block with front mark facing timing belt end of engine. (Scheme 33)
2. Connecting rod and back of rod bearing are stamped with size mark ("1", "2", "3" or "4"). (Scheme 35) Size marks on connecting rod and rod bearing must be the same. Rod bearing thickness is determined by size mark. See «ROD BEARING SPECIFICATIONS»(ref-159137-S31693072252003111300000) table. NOTE: If replacing rod bearing, ensure size mark on replacement rod bearing is the same as size mark on original rod bearing. Ensure size mark is also the same as that stamped on connecting rod.
3. Use caliper to measure outside diameter of connecting rod bolt, just above threads. Replace connecting rod bolt if outside diameter is less than.276 in. (7.01 mm).
4. Ensure piston and connecting rod are installed in cylinder block with front mark facing timing belt end of engine. Ensure protrusion on connecting rod cap is facing timing belt end of engine. (Scheme 33)
5. Coat threads and bolt head-to-connecting rod cap contact surface on connecting rod bolts with engine oil before tightening to specification. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000).
6. Ensure bearing oil clearance and connecting rod side play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-159137-S17955087372003111300000) table and «CONNECTING RODS»(ref-159137-S05575642342003111300000) table under ENGINE SPECIFICATIONS.

ROD BEARING SPECIFICATIONS

Scheme 35

Crankshaft & Main Bearings

1. Remove main bearing cap side bolts (hexagon bolts) from side of cylinder block in sequence. Perform step 1) in illustration. (Scheme 36) Remove main bearing caps side bolts and seal washers.
2. Remove main bearing cap-to-cylinder block bolts (12-point bolts) from cylinder block in sequence. Perform step 2) in illustration. (Scheme 36)
3. Note location of main bearing caps. Main bearing caps are numbered on top of cap for location with No. 1 at timing belt end of engine and No. 4 at drive plate end. Arrow on top of main bearing cap must point toward timing belt end of engine. Remove main bearing caps, crankshaft, main bearings and thrust bearings.
4. Cylinder block main bearing bore inside diameter is determined by size mark stamped on front of cylinder block. (Scheme 37) Left size mark indicates No. 1 main bearing bore and far right size mark indicates No. 4 main bearing bore.
5. Crankshaft journal diameter is identified by size mark located on crankshaft counterweight. (Scheme 37) Ensure journal diameter, taper and out-of-round are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-159137-S17955087372003111300000) table under ENGINE SPECIFICATIONS.
6. Main bearing size mark is located on side of main bearing. (Scheme 37) If replacing main bearing, ensure size mark on replacement main bearing is the same as size mark on original main bearing.
7. If size mark on original main bearing cannot be obtained, use size marks on cylinder block and crankshaft to determine size mark of main bearing to be used. (Scheme 38) Main bearing thickness is identified by size mark on back of bearing. See «MAIN BEARING SPECIFICATIONS»(ref-159137-S41968298092003111300000) table. MAIN BEARING SPECIFICATIONS Size Mark Bearing Thickness - In. (mm) "1".0979-.0980 (2.486-2.489) "2".0980-.0981 (2.489-2.492) "3".0981-.0982 (2.492-2.495) "4".0982-.0983 (2.495-2.498) "5".0983-.0985 (2.498-2.501) "6".0985-.0986 (2.501-2.504) "7".0986-.0987 (2.504-2.507)
8. Use Plastigage to check main bearing oil clearance. Coat threads of main bearing bolts and bolt head-to-main bearing cap area with engine oil. Install wide main bearings in No. 1 and 4 positions, and narrow main bearings in No. 2 and 3 bearing locations.
9. Ensure all main bearings installed in cylinder block contain oil holes. Lower main bearings, installed in main bearing caps, do not have oil holes.
10. Install thrust bearings on No. 2 main bearing in cylinder block and main bearing cap with grooved sides facing outward, toward crankshaft. Install crankshaft and main bearing caps. CAUTION: Main bearing caps must be installed with arrow on top of cap pointing toward timing belt end of engine. Ensure main bearing caps are installed in numerical order, with No. 1 at timing belt end of engine and No. 4 at drive plate end.
11. Install and tighten main bearing cap-to-cylinder block bolts (12-point bolts) to specification in sequence using several steps. Perform step 1) in illustration. (Scheme 39) See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000). NOTE: NEW seal washers must be installed on main bearing cap side bolts (hexagon bolts) during final assembly.
12. Install and tighten main bearing cap side bolts (hexagon bolts) to specification in sequence using several steps. Perform step 2) in illustration. (Scheme 39) See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000).
13. Check crankshaft end play using a dial indicator while prying crankshaft forward and rearward. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(ref-159137-S17955087372003111300000) table under ENGINE SPECIFICATIONS. Replace thrust bearing if crankshaft end play is not within specification.

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Cylinder Block

1. Inspect cylinder block deck surface warpage. Replace cylinder block if deck warpage exceeds specification. See «CYLINDER BLOCK»(ref-159137-S12609165022003111300000) table under ENGINE SPECIFICATIONS.
2. Measure cylinder bore diameter at .39 in. (10.0 mm) from top and bottom of cylinder bore and at middle of cylinder bore. Replace cylinder block if cylinder bore diameter is not within specification. See «CYLINDER BLOCK»(ref-159137-S12609165022003111300000) table under ENGINE SPECIFICATIONS.
3. Ensure main bearing bore inside diameter is within specification with main bearing caps installed and bolts tightened to specification. See «CYLINDER BLOCK»(ref-159137-S12609165022003111300000) table under ENGINE SPECIFICATIONS. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000) .

Note. Main bearing bore inside diameter is determined by size mark stamped on front of cylinder block. (Scheme 37)

Oil Pressure

With engine at normal operating temperature, oil pressure should be at least 4.3 psi (0.3 kg/cm 2 ) at idle, and 43-78 psi (3.0-5.5 kg/cm 2 ) at 3000 RPM.