Engine Mechanical: Removal & Installation Lexus ES XV30

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on engine hood and other major assemblies before removal.

Removal

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159137-S34736421792003111300000). Remove battery and battery tray. Remove hood. Remove right hand fender apron seal. Drain cooling system, engine oil and transaxle fluid. Remove accessory belts.
2. Remove air intake duct with air cleaner assembly and air cleaner case. Disconnect electrical connectors, coolant hoses and on A/T models, transmission oil cooler lines (at transaxle). Remove generator assembly. Remove the 4 bolts and the engine moving control rod with bracket. Remove engine mount brackets on right side of engine. Remove generator bracket. Remove generator adjusting bar. Disconnect wiring from A/C compressor. Remove compressor drive belt. Remove 4 bolts, nut and adjusting bar bracket from compressor. Remove A/C compressor with hoses attached, and secure aside. Disconnect control cable assembly from transaxle.
3. Disconnect power steering reservoir to pump hose. Disconnect the return hose at the tube sub-assembly. Disconnect fuel vapor feed hose and fuel pipe sub-assembly. Remove brake booster vacuum hose from air intake chamber. Disconnect radiator inlet and outlet hoses. Disconnect heater hoses. Remove 2 vacuum hoses from ACIS vacuum tank.
4. From inside passenger compartment, remove glove compartment door assembly. Disconnect the engine wire harness from ECM and junction block. Disconnect the engine wire from engine room junction block. Remove the nut fixing the wire harness. Using a screwdriver, unlock the engine room junction block. Disconnect the engine wire by pulling it upward. Disconnect the connectors. Pull out the engine wire. Remove the body ground.
5. Remove front exhaust pipe. Remove front stabilizer link assembly (left and right side).
6. Remove front axle shaft hub nut (left and right side). Using SST (09930-00010) and a hammer, unstake the staked part of the lock nut. Remove speed sensor (left and right side, with ABS). See appropriate AXLE SHAFTS - FWD article in DRIVE AXLES.
7. Disconnect outer tie rod assembly (left and right side). Remove the cotter pin and a castle nut. Using SST (09628-62011), disconnect the tie rod end from the steering knuckle. Disconnect lower control arm (left and right side). Remove the bolt and 2 nuts. Using a plastic hammer, disconnect the drive shaft from the axle hub.
8. Remove the steering intermediate shaft sub-assembly. Loosen the sliding yoke bolt. Place matchmarks on the steering intermediate shaft and control valve shaft. Remove the bolt, and the steering intermediate shaft. To prevent the steering wheel from rotating, fix the wheel with seat belt. This operation is useful to prevent damaging the spiral cable.
9. Install the No. 2 Engine Hanger (12282-20020) and Bolt (91621-60822) in the correct direction. (Scheme 5) Tighten to 14 ft. lbs. (20 Nm). Set the engine lift into place. Remove the 4 bolts, 2 nuts and frame side rail plate sub-assembly (left and right side). Remove the 4 bolts, 2 nuts and front suspension member brace (rear, left and right side). Lift engine out of vehicle slowly and carefully. Ensure engine is clear of all wiring, hoses and cables. Place engine and transaxle assembly onto stand. Front and rear mounting insulators can be removed. Transaxle can be separated from engine, if needed.

Scheme 5

Installation

To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . When installing transaxle to engine, use threadlock sealant on ends of drive plate mounting bolts. When installing exhaust pipe, install NEW gaskets and mounting nuts. Refill fluids. Start engine and check for leaks. Road test vehicle.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159137-S34736421792003111300000). Disconnect negative battery cable. Remove suspension upper brace. Remove right fender apron seal. Drain cooling system. Remove air cleaner cap assembly and air filter. Remove front exhaust pipe. Remove right engine mount stay. Disconnect connectors from right exhaust manifold. Remove bolt, nut and manifold stay. Remove 6 nuts, right exhaust manifold. Discard gasket.
2. Remove nuts, clips, and "V" bank cover. Remove air intake chamber assembly after disconnecting throttle control motor connector, TP sensor connector and other wiring and hoses, as equipped.
3. 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.
4. Disconnect wiring connectors and hoses from water outlet housing. Remove 2 bolts, 2 nuts and 2 plate washers and remove water outlet housing.
5. Remove generator drive belt. Remove power steering pump. Remove ignition coils. Remove timing belt. See «TIMING BELT REPLACEMENT - 3.0L V6»(ref-156551). Remove camshaft timing pulleys and No. 2 idler pulley.
6. Remove wiring clamps from rear timing belt cover. Remove 6 bolts and remove rear timing belt cover. Disconnect engine wiring and protectors from rear of engine, from both cylinder heads, and from water inlet. Disconnect engine wiring from right and left sides of engine.
7. Disconnect cylinder head rear plate from left cylinder head. Remove water inlet pipe from left cylinder head and water inlet. Discard "O" ring from inlet pipe.
8. Remove power steering pump bracket.
9. Disconnect connectors from left exhaust manifold. Remove bolt, nut and manifold stay. Remove 6 nuts, left exhaust manifold. Discard gasket.
10. Remove dipstick and guide. Remove and discard "O" ring from dipstick guide. Remove cylinder head covers and gaskets. Remove camshafts. See «CAMSHAFT»(ref-159137-S20806121372003111300000). Disconnect the VVT sensor connector. Disconnect the camshaft timing oil control valve connector. Remove the bolt and disconnect the ground cable.
11. Using an 8-mm hexagon wrench, remove recessed cylinder head bolts. Loosen 8 12-point cylinder head bolts in sequence using several steps. see scheme 16 Remove cylinder head.

1. Install NEW cylinder head gaskets on cylinder block. Ensure identification mark faces in correct direction. (Scheme 6) Ensure all holes in cylinder head gaskets align with cylinder block.
2. Install cylinder head. Apply engine oil onto cylinder head bolt threads and cylinder head bolt-to-cylinder head contact surfaces. Install plate washers on bolts. Install and tighten 12-point cylinder head bolts to specification in sequence using several passes. see scheme 16 See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000).
3. Reference mark front cylinder head bolt head. Retighten cylinder head bolts to 90 degrees. Ensure painted mark is positioned at 90 degree angle. (Scheme 7)
4. Install recessed cylinder head bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000). Install camshafts using proper procedure. See «CAMSHAFT»(ref-159137-S20806121372003111300000).
5. If new cylinder head is installed, spark plug tubes must be replaced. Apply 3 bond adhesive to end of tubes. Press in spark plug tubes until tubes protrude 1.669-1.709 in. (42.2-43.4 mm) above cylinder head.
6. Remove old packing material. Apply sealant to grooves of semi-circular plugs and install 2 semi-circular plugs to cylinder head. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000).
7. Before installing valve cover and gasket, apply sealant at front and rear areas of cylinder head. see scheme 6 Using NEW gasket, install valve cover. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000).
8. To install remaining components, reverse removal procedure. If camshaft or cylinder head components are serviced, adjust valve clearance. See «VALVE CLEARANCE»(ref-159137-S41083068472003111300000) under ADJUSTMENTS. When installing intake manifold delivery pipe and injectors, tighten bolts and nuts in several passes in sequence. (Scheme 8) Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000). Fill engine with oil and coolant. Check for leaks.

Scheme 6

Scheme 7

Scheme 8

Removal & Installation (Oil Pump Installed)

1. Remove timing belt and crankshaft sprocket. See «TIMING BELT REPLACEMENT - 3.0L V6»(ref-156551) . Using a knife, cut off oil seal lip. Pry oil seal from oil pump body. DO NOT damage sealing surfaces.
2. To install, apply grease to lip of new oil seal. Using hammer and Oil Seal Installer (SST 09223-00010), install oil seal until surface is even with oil pump body. To install remaining components, reverse removal procedure.

Removal & Installation (Oil Pump Removed)

Pry oil seal from oil pump body. To install, use hammer and Oil Seal Installer (SST 09223-00010). Install oil seal until surface is even with oil pump body. Apply grease to seal lip of oil seal.

Remove camshaft. See CAMSHAFT . Note location of adjusting shims and valve lifters for reassembly reference. Remove adjusting shims and valve lifters from cylinder head.

To install, reverse removal procedure. Ensure components are installed in original location. If camshaft, adjusting shim or valve lifter are replaced, check valve clearance. See VALVE CLEARANCE under ADJUSTMENTS.

1. If reassembling exhaust camshaft, install gear spring so ends contact pins on main gear and sub-gear. (Scheme 12) Install gear spring, camshaft sub-gear, wave washer and snap ring. Using spanner wrench, rotate sub-gear counterclockwise until holes in main gear and sub-gear are aligned. Install service bolt "A". (Scheme 11)
2. Apply engine oil to thrust surfaces and journals of camshafts. Install exhaust camshaft in cylinder head. Rotate exhaust camshaft so timing marks (2 dots) on right cylinder head, or (1 dot) on left cylinder head are positioned at 90 degree angle to cylinder head. (Scheme 15)
3. Apply grease to seal lip on NEW oil seal. Install oil seal on exhaust camshaft. Apply sealant on No. 1 exhaust camshaft bearing cap at bearing cap-to-cylinder head surface.
4. Install exhaust camshaft bearing caps in numerical order. Ensure arrow on top of camshaft bearing cap is pointing toward timing belt end of engine. (Scheme 16)
5. Coat camshaft bearing cap bolt-to-camshaft bearing cap surface and bolt threads with engine oil. Install and tighten exhaust camshaft bearing cap bolts to specification in sequence using several steps. (Scheme 17) See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000).
6. When installing intake camshaft in cylinder head, rotate camshafts so timing marks align (2 dots on right cylinder head, 1 dot on left cylinder head). (Scheme 9)
7. Install intake camshaft bearing caps in numerical order. Ensure arrow on top of camshaft bearing cap is pointing toward timing belt end of engine. (Scheme 16)
8. Coat camshaft bearing cap bolt-to-camshaft bearing cap surface, and bolt threads with engine oil. Install and tighten intake camshaft bearing cap bolts to specification in sequence using several steps. (Scheme 17) See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000). CAUTION: Ensure service bolt "A" is removed from sub-gear on exhaust camshafts.
9. Remove service bolt "A" from exhaust camshaft. Check and adjust valve clearance. See «VALVE CLEARANCE»(ref-159137-S41083068472003111300000) under ADJUSTMENTS.
10. Apply sealant to grooves of semi-circular plugs and install in cylinder head (if removed). Before installing valve cover and gasket, apply sealant at front and rear areas of cylinder head. see scheme 6
11. 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 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Remove transaxle and drive plate. See REMOVAL & INSTALLATION article under SERVICING A/T under AUTOMATIC TRANSMISSION in TRANSAXLE/TRANSMISSION. Using a knife, cut off oil seal lip. Pry oil seal from crankshaft rear oil seal housing. DO NOT damage sealing surfaces.

1. Ensure all sealing surfaces are clean. Apply grease to lip of new oil seal. Using Oil Seal Installer (SST 09223-15030), install oil seal in crankshaft rear oil seal housing until oil seal is even with housing surface.
2. Apply Loctite to drive plate bolts. Install and tighten drive plate bolts to specification in a crisscross pattern. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000) . To install remaining components, reverse removal procedure.

1. Disconnect negative battery cable. Drain cooling system. Remove timing belt, camshaft sprockets and No. 2 idler pulley. See «TIMING BELT REPLACEMENT - 3.0L V6»(ref-156551) .
2. Remove No. 3 (rear) timing belt cover. Remove bolts, nuts, water pump and gasket.

To install, reverse removal procedure using NEW gaskets. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Ensure proper procedure is followed when installing timing belt. Fill cooling system.

1. Disconnect negative battery cable. Remove front upper suspension brace inside engine compartment. Raise and support vehicle. Drain engine oil. Remove right front wheel and fender apron seal. Remove generator and A/C compressor from engine. Remove power steering drive belt and adjusting strut. Remove front exhaust pipe from between exhaust manifolds and catalytic converter.
2. Remove oil level sensor from lower corner of engine block. Remove timing belt. See «TIMING BELT REPLACEMENT - 3.0L V6»(ref-156551). Remove timing pulleys and No. 3 timing belt cover. Remove A/C compressor and housing bracket.
3. Remove No. 2 oil pan bolts and nuts. Install Seal Cutter (SST 09032-00100) between No. 1 and 2 oil pans. Carefully tap seal cutter around No. 2 oil pan to loosen seal. DO NOT damage sealing surfaces. Remove No. 2 oil pan.
4. Remove oil strainer and gasket. (Scheme 18) Remove 2 bolts and flywheel housing undercover located at rear of No. 1 oil pan. Remove exhaust pipe stay, if equipped. Remove 19 bolts. Using screwdriver, remove oil pan by prying portions between cylinder block and oil pan. Remove No. 1 oil pan. NOTE: DO NOT damage contact surfaces of cylinder block and oil pan.
5. Remove baffle plate from No. 1 oil pan. Remove crankshaft position sensor. (Scheme 18)

Scheme 18

1. Install crankshaft position sensor. Install baffle plate on No. 1 oil pan (if necessary). Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000).
2. Ensure sealing surfaces are clean. Apply Seal Packing (08826-00080) or equivalent to No. 1 oil pan. (Scheme 19) Install oil pan and tighten bolts to specifications. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000).
3. Install flywheel housing undercover and exhaust pipe support stay, if equipped. Install oil strainer.
4. Apply seal packing to No. 2 oil pan. (Scheme 19) Ensure seal width is.118-.197 in. (3.0-5.0 mm). Install No. 2 oil pan with 19 bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000).
5. Install NEW gasket to oil level sensor. Install oil level sensor. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000). To install remaining components, reverse removal procedure.

Scheme 19

Removal & Disassembly

Remove No. 1 and 2 oil pans. See OIL PAN under REMOVAL & INSTALLATION. Remove 9 bolts, oil pump and "O" ring. Remove oil pump body cover and oil pump components. (Scheme 20)

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure both rotors are installed in oil pump body with identification mark (triangle mark) facing oil pump body cover. Install oil pump body cover.
2. Using NEW gasket, install and tighten relief valve plug to specification. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000) . Using Oil Seal Installer (SST 09223-00010), install crankshaft front seal (if removed) until surface is even with oil pump body. Coat seal lip with grease.
3. To install, apply sealant on rear of oil pump. Install NEW "O" ring on cylinder block. Install oil pump. Ensure splined teeth on drive rotor of oil pump engages with splines on crankshaft.
4. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159137-S23585106052003111300000) . To install remaining components, reverse removal procedure.

Scheme 20