Engine Mechanical: Overview Lexus ES XV40

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1. INSPECT ENGINE COOLANT Inspect the engine coolant (See «ON-VEHICLE INSPECTION»(/lexus/es/xv40-2006-2009/remont/cooling-fan/#engine-cooling-system) ).
2. INSPECT ENGINE OIL Inspect the engine oil (See «LUBRICATION SYSTEM»(/lexus/es/xv40-2006-2009/remont/lubrication-system/#lubrication) ).
3. INSPECT BATTERY Inspect the battery (See «ON-VEHICLE INSPECTION»(ref-283097-S19047281252008041700000) ).
4. INSPECT SPARK PLUGS Inspect the spark plugs (See «ON-VEHICLE INSPECTION»(ref-283096-S16692917832008041700000) ).
5. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY Remove the air cleaner filter element sub-assembly. Visually check that there is no dirt, blockage, and/or damage to the air cleaner filter element. HINT: If there is any dirt or a blockage in the air cleaner filter element, clean it with compressed air. If any dirt or a blockage remains even after cleaning the air cleaner filter element with compressed air, replace it.
6. INSPECT VALVE LASH ADJUSTER NOISE Rev up the engine several times. Check that the engine does not emit unusual noises. If unusual noises occur, warm up the engine and idle it for over 30 minutes. Then repeat this procedure. HINT: If any defects or problems are found during the inspection above, perform lash adjuster inspection (See «INSPECTION»(ref-283093-S03920934732008041700000) ).
7. INSPECT IGNITION TIMING Warm up the engine. When using the intelligent tester: Check the ignition timing. Connect the intelligent tester to the DLC3. Enter DATA LIST mode with the intelligent tester. Ignition timing: 8 to 12° BTDC at idle HINT: Refer to the intelligent tester operator's manual for help when selecting the DATA LIST. When not using the intelligent tester: Check the ignition timing. Using SST, connect terminals 13 (TC) and 4 (CG)of the DLC3. SST 09843-18040 NOTE: Confirm the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine. Turn off all electrical systems before connecting the terminals. Perform this inspection after the cooling fan motor is turned off. Remove the cool air intake duct seal. (See «REMOVAL»(ref-283093-S19183759882008041700000) ) Remove the engine room side cover LH. (See «REMOVAL»(ref-283093-S19183759882008041700000) ) Remove the engine room side cover RH. (See «REMOVAL»(ref-283093-S19183759882008041700000) ) Remove the V-bank cover. (See «REMOVAL»(ref-283093-S19183759882008041700000) ) Pull out the red lead wire harness. Connect the tester terminal of the timing light to the red lead wire as shown in the illustration. NOTE: Use a timing light which can detect the first signal. Check the ignition timing at idle. Ignition timing: 8 to 12° BTDC at idle NOTE: When checking the ignition timing, the transmission should be in neutral. HINT: Run the engine at 1,000 to 1,300 rpm for 5 seconds, and then check that the engine rpm returns to idle speed. disconnect terminals 13 (TC) and 4 (CG) of the DLC3. Check the ignition timing at idle. Ignition timing: 12 to 22° BTDC at idle Confirm that the ignition timing moves to the advanced angle side when the engine rpm is increased. Remove the timing light.
8. INSPECT ENGINE IDLE SPEED Warm up the engine. When using the intelligent tester: Check the idle speed. Connect the intelligent tester to the DLC3. Enter DATA LIST mode with the intelligent tester. Idle speed: 600 to 700 rpm NOTE: When checking the idle speed, the transmission should be in neutral. Check the idle speed with the cooling fan off. Switch off all accessories and air conditioning before connecting the intelligent tester. HINT: Refer to the intelligent tester operator's manual for further details. When not using the intelligent tester: Check the idle speed. Using SST, connect the tachometer test probe to terminal 9 (TAC) of the DLC3. SST 09843-18030 Check the idle speed. Idle speed: 600 to 700 rpm
9. INSPECT COMPRESSION Warm up and stop the engine. Disconnect the injector connectors. Remove the intake air surge tank (See «REMOVAL»(/lexus/es/xv40-2006-2009/remont/fuel-system/#fuel) ). Remove the 6 ignition coils. Remove the 6 spark plugs. Check the cylinder compression pressure. Insert a compression gauge into the spark plug hole. While cranking the engine, measure the compression pressure. Compression pressure: 1.4 MPa (14 kgf/cm 2 , 199 psi) Minimum pressure: 0.98 MPa (10 kgf/cm 2 , 142 psi) Difference between each cylinder: 0.1 MPa (1.0 kgf/cm 2 , 15 psi) NOTE: Always use a fully charged battery to obtain an engine speed of 250 rpm or more. Check the other cylinders' compression pressure in the same way. This measurement must be done as quickly as possible. If the cylinder compression is low, pour a small amount of engine oil into the cylinder through the spark plug hole and inspect again. HINT: If adding oil increases the compression, the piston rings and/or cylinder bore may be worn or damaged. If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket. Install the 6 spark plugs. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) Install the 6 ignition coils. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Install the intake air surge tank. (See «INSTALLATION»(/lexus/es/xv40-2006-2009/remont/fuel-system/#fuel__installation) )
10. INSPECT CO/HC Start the engine. Run the engine at 2,500 rpm for approximately 180 seconds. Insert the CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling. Check CO/HC concentration at idle and/or 2,500 rpm. HINT: Check regulations and restrictions in your area when performing 2 mode CO/HC concentration testing (engine check at both idle speed and at 2,500 rpm). If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below. Check A/F sensor and heated oxygen sensor operation. See the table below for possible causes, and then inspect and repair. CO/HC PROBLEMS CHART CO HC Problems Causes Normal High Rough idle Faulty ignitions: Incorrect timing Fouled, shorted or improperly gapped plugs Incorrect valve clearance Leaks in intake and exhaust valves Leaks in cylinders Low High Rough idle (fluctuating HC reading) Vacuum leaks: PCV hoses Intake manifold Throttle body Brake booster line Lean mixture causing misfire High High Rough idle (black smoke from exhaust) Restricted air filter Plugged PCV valve Faulty SFI system: Faulty fuel pressure regulator Defective ECT sensor Defective MAF meter Faulty ECM Faulty injectors Faulty throttle position sensor

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1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE COOL AIR INTAKE DUCT SEAL (See «REMOVAL»(ref-283093-S19183759882008041700000) )
4. REMOVE ENGINE ROOM SIDE COVER LH (See «REMOVAL»(ref-283093-S19183759882008041700000) )
5. REMOVE ENGINE ROOM SIDE COVER RH (See «REMOVAL»(ref-283093-S19183759882008041700000) )
6. REMOVE V-BANK COVER SUB-ASSEMBLY (See «REMOVAL»(ref-283093-S19183759882008041700000) )
7. REMOVE V-RIBBED BELT While releasing the belt tension by turning the belt tensioner counterclockwise, remove the V-ribbed belt from the belt tensioner. While turning the belt tensioner counterclockwise, align with its holes, and then insert the 5 mm bi-hexagon wrench into the holes to fix the V-ribbed belt tensioner.

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1. INSPECT V-RIBBED BELT Visually check the V-ribbed belt for excessive wear, frayed cords, etc. If any defect has been found, replace the V-ribbed belt. HINT: Cracks on the rib side of a V-ribbed belt are considered acceptable. If the drive belt has chunks missing from its ribs, it should be replaced. HINT: A "new belt" is a belt which has been used for less than 5 minutes with the engine running. A "used belt" is a belt which has been used for 5 minutes or more with the engine running.
2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY Check that nothing gets caught in the tensioner by turning it clockwise and counterclockwise. If a malfunction exists, replace the tensioner.

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1. INSTALL V-RIBBED BELT Install the V-ribbed belt. While turning the belt tensioner counterclockwise, remove the bar. If it is difficult to install the V-ribbed belt, perform the following procedure: Put the V-ribbed belt on every pulley except the tensioner pulley as shown in the illustration. While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-ribbed belt on the tensioner pulley. NOTE: Put the backside of the V-ribbed belt on the tensioner pulley and idler pulley. Check that the V-ribbed belt is properly set to each pulley. After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by hand.
2. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-283093-S25114169122008041700000) )
3. INSTALL ENGINE ROOM SIDE COVER RH (See «INSTALLATION»(ref-283093-S25114169122008041700000) )
4. INSTALL ENGINE ROOM SIDE COVER LH (See «INSTALLATION»(ref-283093-S25114169122008041700000) )
5. INSTALL COOL AIR INTAKE DUCT SEAL (See «INSTALLATION»(ref-283093-S25114169122008041700000) )
6. INSTALL FRONT FENDER APRON SEAL RH
7. INSTALL FRONT WHEEL RH Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)

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1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE COOL AIR INTAKE DUCT SEAL (See «REMOVAL»(ref-283093-S19183759882008041700000) )
4. REMOVE ENGINE ROOM SIDE COVER LH (See «REMOVAL»(ref-283093-S19183759882008041700000) )
5. REMOVE ENGINE ROOM SIDE COVER RH (See «REMOVAL»(ref-283093-S19183759882008041700000) )
6. REMOVE V-BANK COVER SUB-ASSEMBLY (See «REMOVAL»(ref-283093-S19183759882008041700000) )
7. REMOVE V-RIBBED BELT (See «REMOVAL»(ref-283093-S00211596642008041700000) )
8. REMOVE CRANKSHAFT PULLEY Using SST, loosen the crankshaft pulley bolt. SST 09213-70011 (09213-70020), 09330-00021 Using SST, remove the crankshaft pulley bolt and crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
9. REMOVE TIMING CHAIN CASE OIL SEAL Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. NOTE: After the removal, check the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper. HINT: Tape the screwdriver tip before use.

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1. INSTALL TIMING CHAIN CASE OIL SEAL Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09316-60011 (09316-00011) Oil seal tap in depth: 0 to 1 mm (0 to 0.039 in.) NOTE: Keep the lip free of foreign matter. Do not tap the oil seal at an angle.
2. INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the pulley, and slide on the pulley. Using SST, install the pulley bolt. SST 09213-70011 (09213-70020), 09330-00021 Torque: 250 N*m (2,550 kgf*cm, 184 ft.*lbf)
3. INSTALL V-RIBBED BELT (See «INSTALLATION»(ref-283093-S36814178942008041700000) )
4. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-283093-S25114169122008041700000) )
5. INSTALL ENGINE ROOM SIDE COVER LH (See «INSTALLATION»(ref-283093-S25114169122008041700000) )
6. INSTALL ENGINE ROOM SIDE COVER RH (See «INSTALLATION»(ref-283093-S25114169122008041700000) )
7. INSTALL COOL AIR INTAKE DUCT SEAL (See «INSTALLATION»(ref-283093-S25114169122008041700000) )
8. INSTALL FRONT FENDER APRON SEAL RH
9. INSTALL FRONT WHEEL RH Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)

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1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT: See «REMOVAL»(/lexus/es/xv40-2006-2009/remont/automatic-trans/#automatic-transaxle-u660e) .
2. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Using SST, hold the crankshaft. SST 09213-70011 (09213-70020), 09330-00021 Remove the 8 bolts, front spacer, drive plate and rear spacer.
3. REMOVE ENGINE REAR OIL SEAL Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. NOTE: Be careful not to damage the crankshaft. HINT: Tape the screwdriver tip before use.

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1. INSTALL ENGINE REAR OIL SEAL Apply MP grease to a new oil seal lip. Using SST and a hammer, tap in the oil seal. SST 09223-15030, 09950-70010 (09951-07150) Oil seal tap in depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.)
2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Using SST, hold the crankshaft. SST 09213-70011 (09213-70020), 09330-00021 Apply adhesive to 2 or 3 threads of the mounting bolt end. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent Install the front spacer, drive plate and rear spacer on the crankshaft. Install and tighten the 8 mounting bolts uniformly in several steps. Torque: 83 N*m (850 kgf*cm, 61 ft.*lbf)
3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY HINT: See «INSTALLATION»(/lexus/es/xv40-2006-2009/remont/automatic-trans/#automatic-transaxle-u660e) .

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1. DISCHARGE FUEL SYSTEM PRESSURE HINT: See «FUEL SYSTEM»(/lexus/es/xv40-2006-2009/remont/fuel-system/#fuel) .
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE FRONT WHEELS
5. REMOVE ENGINE UNDER COVER LH
6. REMOVE ENGINE UNDER COVER RH
7. REMOVE FRONT FENDER APRON SEAL RH
8. DRAIN ENGINE OIL (See «REPLACEMENT»(/lexus/es/xv40-2006-2009/remont/lubrication-system/#lubrication__replacement) )
9. DRAIN ENGINE COOLANT (See «COOLANT»(/lexus/es/xv40-2006-2009/remont/cooling-fan/#engine-cooling-system) )
10. DRAIN AUTOMATIC TRANSAXLE FLUID (See «REMOVAL»(/lexus/es/xv40-2006-2009/remont/automatic-trans/#automatic-transaxle-u660e) )
11. REMOVE COOL AIR INTAKE DUCT SEAL Remove the 7 clips and intake duct seal.
12. REMOVE ENGINE ROOM SIDE COVER LH Remove the hood hinge cover LH. Remove the 6 clips and engine room side cover LH.
13. REMOVE ENGINE ROOM SIDE COVER RH Remove the hood hinge cover RH. Remove the 5 clips and engine room side cover RH.
14. REMOVE V-BANK COVER SUB-ASSEMBLY Hold the front of the V-bank cover and raise it to disengage the 2 clips on the front of the cover. Continue to raise the cover to disengage the clip on the rear of the cover and remove the cover. NOTE: Attempting to disengage both front and rear clips at the same time may cause the cover to break.
15. REMOVE V-RIBBED BELT (See «REMOVAL»(ref-283093-S00211596642008041700000) )
16. REMOVE AIR CLEANER INLET ASSEMBLY Remove the 2 bolts, clamp and air cleaner inlet.
17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See «ON-VEHICLE INSPECTION»(/lexus/es/xv40-2006-2009/remont/testing-diagnostics/#engine-control-system) )
18. REMOVE AIR CLEANER CASE SUB-ASSEMBLY Disconnect the vacuum hose and hose clamp. Remove the 3 bolts and air cleaner case.
19. REMOVE NO. 1 AIR CLEANER INLET Remove the bolt and No. 1 air cleaner inlet.
20. REMOVE BATTERY Loosen the nut, and remove the bolt and battery clamp. Remove the battery and battery tray.
21. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY Remove the clip, bolt and intake air resonator.
22. REMOVE NO. 2 ENGINE MOUNTING STAY RH Remove the bolt, 2 nuts, and No. 2 mounting stay RH.
23. REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY Remove the 4 bolts and engine moving control rod.
24. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE Remove the clamp and disconnect the No. 1 fuel vapor feed hose.
25. DISCONNECT CHECK VALVE TO BRAKE BOOSTER HOSE Remove the clamp and disconnect the check valve to brake booster hose.
26. REMOVE RADIATOR HOSE INLET Remove the clamp and disconnect the radiator hose inlet.
27. REMOVE RADIATOR HOSE OUTLET Remove the clamp and disconnect the radiator hose outlet.
28. DISCONNECT NO. 1 OIL COOLER INLET HOSE Remove the clamp and disconnect the oil cooler inlet hose.
29. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE Remove the clamp and disconnect the oil cooler outlet hose.
30. DISCONNECT HEATER INLET WATER HOSE Disconnect the heater inlet water hose.
31. DISCONNECT HEATER OUTLET WATER HOSE Disconnect the heater outlet water hose.
32. REMOVE ECM HINT: See «REMOVAL»(/lexus/es/xv40-2006-2009/remont/testing-diagnostics/#engine-control-system) .
33. REMOVE RELAY BLOCK COVER UPPER
34. DISCONNECT ENGINE WIRE Disconnect the engine wire from the engine room junction block. Remove the nut and separate the wire harness. Using a screwdriver, unlock the engine room junction block. Pull the engine room J/B upward. Disconnect the engine wire connectors. Remove the 2 bolts and 2 clamps from the body. Remove the bolt and clamp from the bracket.
35. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Remove the clip and nut, and separate the cable from the transaxle.
36. SEPARATE FUEL TUBE SUB-ASSEMBLY Remove the No. 1 fuel pipe clamp. Disconnect the connector from the tube while pinching part A with your fingers as shown in the illustration. NOTE: Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector. Disconnect the connector by hand. Do not bend, fold or rotate the nylon tube. If the pipe and connector are stuck together, push and pull the connector until it becomes free. Put the pipe and connector ends in vinyl bags to prevent damage and contamination.
37. DISCONNECT OIL RESERVOIR TO PUMP HOSE Disconnect the oil reservoir to pump hose.
38. DISCONNECT RETURN TUBE SUB-ASSEMBLY Disconnect the return tube sub-assembly.
39. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET (See «REMOVAL»(/lexus/es/xv40-2006-2009/remont/exhaust/#exhaust) )
40. REMOVE EXHAUST PIPE ASSEMBLY FRONT (See «REMOVAL»(/lexus/es/xv40-2006-2009/remont/exhaust/#exhaust) )
41. REMOVE FRONT AXLE HUB NUT LH (See «REMOVAL»(ref-283112-S32953777222008041700000) )
42. REMOVE FRONT AXLE HUB NUT RH HINT: Use the same procedure described for the LH side.
43. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH (See «REMOVAL»(ref-283112-S32953777222008041700000) )
44. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure described for the LH side.
45. DISCONNECT FRONT SPEED SENSOR LH (See «REMOVAL»(ref-283112-S32953777222008041700000) )
46. DISCONNECT FRONT SPEED SENSOR RH HINT: Use the same procedure described for the LH side.
47. DISCONNECT TIE ROD ASSEMBLY LH (See «REMOVAL»(ref-283112-S32953777222008041700000) )
48. DISCONNECT TIE ROD ASSEMBLY RH HINT: Use the same procedure described for the LH side.
49. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM LH (See «REMOVAL»(ref-283112-S32953777222008041700000) )
50. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM RH HINT: Use the same procedure described for the LH side.
51. SEPARATE FRONT AXLE ASSEMBLY LH (See «REMOVAL»(ref-283112-S32953777222008041700000) )
52. SEPARATE FRONT AXLE ASSEMBLY RH HINT: Use the same procedure described for the LH side.
53. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET Remove the No. 1 exhaust pipe support bracket with the 2 nuts.
54. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH CETTING BOLT (See «REMOVAL»(/lexus/es/xv40-2006-2009/remont/automatic-trans/#automatic-transaxle-u660e) )
55. DISCONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY (See «REMOVAL»(ref-283113-S23346816882008041700000) )
56. REMOVE GENERATOR ASSEMBLY (See «REMOVAL»(ref-283097-S02944761222008041700000) )
57. SEPARATE COOLER COMPRESSOR ASSEMBLY Remove the 2 connector clamps. Remove the 4 bolts and separate the compressor. HINT: Hang up the hoses instead of detaching them.
58. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE Set the engine lifter. Remove the 4 bolts, 2 nuts, and frame side rail plates RH and LH. Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH. Operate the engine lifter, then remove the engine assembly from the vehicle. NOTE: Make sure that the engine is clear of all wiring and hoses.
59. REMOVE VANE PUMP ASSEMBLY Disconnect the power steering oil pressure switch connector. Remove the pressure feed tube clamp bolt C. Loosen the bolt A. Remove the bolt B and vane pump.
60. INSTALL ENGINE HANGER Install the 2 engine hangers with the 4 bolts as shown in the illustration. Part No: No. 1 Engine hanger 12281-31120 No. 2 Engine hanger 12282-31100 Bolts 91671-10825 Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) Attach the engine sling device and hang the engine with the chain block.
61. REMOVE FRONT FRAME ASSEMBLY Disconnect the 2 connectors and 2 clamps. Disconnect the 2 clamps. Remove the 2 nuts and disconnect the engine mounting insulators RH and LH. Remove the 2 bolts and disconnect the engine mounting insulator FR and cable.
62. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See «REMOVAL»(ref-283112-S32953777222008041700000) )
63. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See «DISASSEMBLY»(ref-283112-S11136590582008041700000) )
64. REMOVE ENGINE WIRE
65. REMOVE STARTER ASSEMBLY (See «REMOVAL»(ref-283102-S04087569972008041700000) )
66. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT: See «REMOVAL»(/lexus/es/xv40-2006-2009/remont/automatic-trans/#automatic-transaxle-u660e) .
67. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (See «REMOVAL»(ref-283093-S37527517312008041700000) )
68. SECURE ENGINE Secure the engine onto an engine stand with the bolts.
69. REMOVE INTAKE AIR SURGE TANK ASSEMBLY HINT: See «REMOVAL»(/lexus/es/xv40-2006-2009/remont/fuel-system/#fuel) .
70. REMOVE IGNITION COIL ASSEMBLY Remove the 6 bolts and 6 ignition coils.
71. REMOVE NO. 2 ENGINE MOUNTING STAY RH Remove the bolt and No. 2 engine mounting stay RH.
72. REMOVE INTAKE MANIFOLD Uniformly loosen and remove the 6 bolts and 4 nuts. Remove the intake manifold and 2 gaskets.
73. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Disconnect the A/F sensor connector clamp. Uniformly loosen and remove the 6 nuts. Remove the manifold and gasket.
74. REMOVE OIL LEVEL GAUGE GUIDE SUB-ASSEMBLY Remove the oil level gauge. Remove the 2 bolts, oil level gauge guides No. 1 and No. 2. Remove the O-rings from the oil level gauge guide.
75. REMOVE NO. 2 MANIFOLD STAY Remove the bolt, nut, and No. 2 manifold stay.
76. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Remove the 3 bolts and No. 2 insulator.
77. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Uniformly loosen and remove the 6 nuts. Remove the manifold and gasket.
78. REMOVE ENGINE MOUNTING BRACKET RH Remove the 3 bolts and engine mounting bracket RH.
79. REMOVE DRIVE SHAFT BEARING BRACKET Remove the 3 bolts and drive shaft bearing bracket.
80. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Remove the 5 bolts and V-ribbed belt tensioner assembly.
81. REMOVE NO. 2 TIMING GEAR COVER Remove the 2 bolts and No. 2 timing gear cover.
82. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY Remove the bolt, plate and No. 2 idler pulley sub-assembly.
83. REMOVE WATER PUMP PULLEY (See «REMOVAL»(/lexus/es/xv40-2006-2009/remont/cooling-fan/#engine-cooling-system) )
84. REMOVE NO. 1 ENGINE MOUNTING BRACKET FRONT LH Remove the 6 bolts and No. 1 engine mounting bracket front LH.
85. REMOVE RADIO SETTING CONDENSER Remove the 2 bolts and 2 radio setting condensers.
86. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY Remove the bolt and No. 1 vacuum switching valve.
87. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
88. REMOVE KNOCK CONTROL SENSOR (See «REMOVAL»(/lexus/es/xv40-2006-2009/remont/testing-diagnostics/#engine-control-system) )
89. REMOVE ENGINE OIL LEVEL SENSOR Remove the 4 bolts, then remove the oil level sensor and gasket.
90. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Using a 19 mm deep socket wrench, remove the EFI engine coolant temperature sensor and gasket.

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1. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head. Maximum warpage: 0.7 mm (0.028 in.) HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.). If the warpage is greater than the maximum, replace the manifold.
2. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head. Maximum warpage: 0.7 mm (0.028 in.) HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.). If the warpage is greater than the maximum, replace the manifold.
3. INSPECT INTAKE AIR SURGE TANK ASSEMBLY Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the intake manifold. Maximum warpage: 2.5 mm (0.098 in.) If the warpage is greater than the maximum, replace the surge tank.
4. INSPECT INTAKE MANIFOLD Cylinder head side: Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.1 mm (0.003 in.) If the warpage is greater than the maximum, replace the intake manifold. Surge tank side: Using a precision straightedge and feeler gauge, measure the surface contacting the surge tank for warpage. Maximum warpage: 0.1 mm (0.003 in.) If the warpage is greater than the maximum, replace the intake manifold.

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Scheme 99

Scheme 100

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Using a 19 mm deep socket wrench, install the engine coolant temperature sensor and a new gasket. Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf)
2. INSTALL ENGINE OIL LEVEL SENSOR Install the engine oil level sensor and a new gasket with the 4 bolts. Torque: 8.2 N*m (84 kgf*cm, 73 in.*lbf)
3. INSTALL KNOCK CONTROL SENSOR (See «INSPECTION»(/lexus/es/xv40-2006-2009/remont/testing-diagnostics/#engine-control-system) )
4. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent Using a 24 mm deep socket wrench, install the oil pressure switch. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) NOTE: Do not start the engine within 1 hour after installation to prevent oil leaks.
5. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY Install the No. 1 vacuum switching valve with the bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
6. INSTALL RADIO SETTING CONDENSER Install the 2 radio setting condensers with the 2 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
7. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT LH Install the No. 1 engine mounting bracket front LH with the 6 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
8. INSTALL WATER PUMP PULLEY (See «INSTALLATION»(/lexus/es/xv40-2006-2009/remont/cooling-fan/#engine-cooling-system) )
9. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Install the No. 2 idler pulley sub-assembies and cover plates with the bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
10. INSTALL NO. 2 TIMING GEAR COVER Install the No. 2 timing gear cover with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
11. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Temporarily install the V-ribbed belt tensioner with the 5 bolts. HINT: Each bolt length is as follows: 70 mm (2.76 in.) 33 mm (1.30 in.) Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Tighten the other bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
12. INSTALL DRIVE SHAFT BEARING BRACKET Install the drive shaft bearing bracket with the 3 bolts. Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
13. INSTALL ENGINE MOUNTING BRACKET RH Install the engine mounting bracket RH with the 3 bolts. Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Install a new gasket as shown in the illustration. Install the exhaust manifold sub-assembly LH with the 6 nuts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
15. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Install the No. 2 insulator with the 3 bolts. Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
16. INSTALL NO. 2 MANIFOLD STAY Install the No. 2 manifold stay with the bolt and nut. Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)
17. INSTALL OIL LEVEL GAUGE GUIDE SUB-ASSEMBLY Install 2 new O-rings to the oil level gauge guide. Apply a light coat of engine oil to the O-rings. Push in the oil level gauge guide end into the guide hole. Install the oil level gauge guide No. 1 with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Install the oil level gauge guide No. 2 with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Install the oil level gauge.
18. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Install a new gasket as shown in the illustration. Install the exhaust manifold sub-assembly RH with the 6 nuts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
19. INSTALL INTAKE MANIFOLD Set a new gasket on each cylinder head. NOTE: Align the port holes of the gasket and cylinder head. Make sure that the gasket is installed in the correct direction. Set the intake manifold on the cylinder heads. Install and tighten the 6 bolts and 4 nuts uniformly in several steps. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
20. INSTALL NO. 2 ENGINE MOUNTING STAY RH Install the No. 2 engine mounting stay RH with the bolt. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
21. INSTALL IGNITION COIL ASSEMBLY Install the 6 ignition coil assemblies with the 6 bolts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
22. INSTALL INTAKE AIR SURGE TANK ASSEMBLY NOTE: DO NOT apply oil to the bolts listed below: TORQUE SPECIFICATION Tightening Parts Surge Tank and Intake Manifold No. 1 Surge Tank Stay and Cylinder Head Cover No. 1 Surge Tank Stay and Surge Tank Throttle Body Bracket and Cylinder Head Cover Throttle Body Bracket and Surge Tank Install a new gasket to the intake air surge tank. Using a 5 mm hexagon socket wrench, install the 4 bolts and 2 nuts. Torque: Bolt 18 N*m (184 kgf*cm, 13 ft.*lbf) Nut 16 N*m (163 kgf*cm, 12 ft.*lbf) Install the throttle body bracket, No. 1 surge tank stay and 4 bolts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) Connect the connector. Install the vacuum hose clamp with the bolt. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) Connect the No. 1 ventilation hose. Install the clamp and connect the throttle with motor body assembly connector. Connect the vapor feed hose. Connect the 2 water by-pass hoses to the throttle with motor body assembly.
23. REMOVE ENGINE STAND
24. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (See «INSTALLATION»(ref-283093-S17907259992008041700000) )
25. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY HINT: See «INSTALLATION»(/lexus/es/xv40-2006-2009/remont/automatic-trans/#automatic-transaxle-u660e) .
26. INSTALL STARTER ASSEMBLY (See «INSTALLATION»(ref-283102-S37470572462008041700000) )
27. INSTALL ENGINE WIRE
28. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See «INSTALLATION»(ref-283112-S24530399672008041700000) )
29. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See «INSTALLATION»(ref-283112-S24530399672008041700000) )
30. INSTALL FRONT FRAME ASSEMBLY Install the engine mounting insulators RH and LH with the 2 nuts. Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) Install the engine mounting insulator FR with the bolt. Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) Connect the cable with the bolt. Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) Connect the 2 connectors and 2 clamps. Connect the 2 clamps.
31. INSTALL VANE PUMP ASSEMBLY Install the vane pump with the 2 bolts. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) Install the pressure feed tube clamp bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) Connect the power steering oil pressure switch connector.
32. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Set the engine assembly with transaxle on the engine lifter. Install the engine assembly to the vehicle. Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts. Torque: A 85 N*m (867 kgf*cm, 63 ft.*lbf) B 32 N*m (329 kgf*cm, 24 ft.*lbf) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts. Torque: C 85 N*m (867 kgf*cm, 63 ft.*lbf) D 32 N*m (329 kgf*cm, 24 ft.*lbf)
33. INSTALL COOLER COMPRESSOR ASSEMBLY Temporarily install the cooler compressor with the 4 bolts. Install the compressor with the 4 bolts by tightening the bolts in the order shown in the illustration. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) Install the 2 connector clamps.
34. INSTALL GENERATOR ASSEMBLY (See «INSTALLATION»(ref-283097-S22447610432008041700000) )
35. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY (See «INSTALLATION»(ref-283113-S21931384412008041700000) )
36. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (See «INSTALLATION»(/lexus/es/xv40-2006-2009/remont/automatic-trans/#automatic-transaxle-u660e) )
37. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET Install the No. 1 exhaust pipe support bracket with the 2 nuts. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) (bolt)
38. INSTALL FRONT AXLE ASSEMBLY LH (See «INSTALLATION»(ref-283112-S24530399672008041700000) )
39. INSTALL FRONT AXLE ASSEMBLY RH HINT: Use the same procedure described for the LH side.
40. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH (See «INSTALLATION»(ref-283112-S24530399672008041700000) )
41. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH HINT: Use the same procedure described for the LH side.
42. INSTALL TIE ROD ASSEMBLY LH (See «INSTALLATION»(ref-283112-S24530399672008041700000) )
43. INSTALL TIE ROD ASSEMBLY RH HINT: Use the same procedure described for the LH side.
44. INSTALL FRONT SPEED SENSOR LH (See «INSTALLATION»(ref-283112-S24530399672008041700000) )
45. INSTALL FRONT SPEED SENSOR RH HINT: Use the same procedure described for the LH side.
46. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See «INSTALLATION»(ref-283112-S24530399672008041700000) )
47. INSTALL FRONT STABILIZER LINK ASSEMBLY RH HINT: Use the same procedure described for the LH side.
48. INSTALL FRONT AXLE HUB NUT LH (See «INSTALLATION»(ref-283112-S24530399672008041700000) )
49. INSTALL FRONT AXLE HUB NUT RH HINT: Use the same procedure described for the LH side.
50. INSTALL EXHAUST PIPE ASSEMBLY FRONT (See «INSTALLATION»(/lexus/es/xv40-2006-2009/remont/exhaust/#exhaust) )
51. INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET (See «INSTALLATION»(/lexus/es/xv40-2006-2009/remont/exhaust/#exhaust) )
52. CONNECT OIL RESERVOIR TO PUMP HOSE Connect the oil reservoir to pump hose.
53. CONNECT RETURN TUBE SUB-ASSEMBLY Connect the return tube sub-assembly.
54. CONNECT FUEL TUBE SUB-ASSEMBLY Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound. NOTE: Check for damage or contamination on the connected part of the pipe. Check if the pipe and the connector are securely connected by trying to pull them apart. Install the No. 1 fuel pipe clamp.
55. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Connect the cable to the transaxle with the clip and nut. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
56. CONNECT ENGINE WIRE Install the clamp to the bracket with the bolt. Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) Install the 2 clamps to the body with the 2 bolts. Torque: Bolt A 12 N*m (123 kgf*cm, 9 ft.*lbf) Bolt B 8.4 N*m (85 kgf*cm, 74 in.*lbf) Connect the engine wire connectors to the engine room junction block. Then, install it with the nut. Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf)
57. INSTALL RELAY BLOCK COVER UPPER
58. INSTALL ECM (See «INSTALLATION»(/lexus/es/xv40-2006-2009/remont/testing-diagnostics/#engine-control-system) )
59. CONNECT HEATER INLET WATER HOSE Connect the heater inlet water hose.
60. CONNECT HEATER OUTLET WATER HOSE Connect the heater outlet water hose.
61. CONNECT NO. 1 OIL COOLER INLET HOSE Install the oil cooler inlet hose with the clamp.
62. CONNECT NO. 1 OIL COOLER OUTLET HOSE Install the oil cooler outlet hose with the clamp.
63. INSTALL RADIATOR HOSE INLET Install the radiator hose inlet with the clamp.
64. INSTALL RADIATOR HOSE OUTLET Install the radiator hose outlet with the clamp.
65. CONNECT CHECK VALVE TO BRAKE BOOSTER HOSE Install the check valve to brake booster hose with the clamp.
66. CONNECT NO. 1 FUEL VAPOR FEED HOSE Install the No. 1 fuel vapor feed hose with the clamp.
67. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY Temporarily install the engine moving control rod with the 4 bolts. Tighten the 4 bolts. Torque: 38 N*m (388 kgf*cm, 28 ft.*lbf)
68. INSTALL NO. 2 ENGINE MOUNTING STAY RH Temporarily install the No. 2 engine mounting stay RH with the bolt and 2 nuts. Tighten the bolt and 2 nuts. Torque: Bolt 38 N*m (388 kgf*cm, 28 ft.*lbf) Nut 23 N*m (235 kgf*cm, 17 ft.*lbf)
69. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY Install the intake air resonator with the bolt and clip. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
70. INSTALL BATTERY Install the battery and battery tray. Install the battery clamp with the bolt and nut. Torque: Bolt 9.0 N*m (92 kgf*cm, 80 in.*lbf) Nut 3.5 N*m (36 kgf*cm, 31 in.*lbf)
71. INSTALL NO. 1 AIR CLEANER INLET Install the No. 1 air cleaner inlet with the bolt. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
72. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Install the air cleaner case with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Connect the vacuum hose and hose clamp.
73. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (See «INSTALLATION»(/lexus/es/xv40-2006-2009/remont/testing-diagnostics/#engine-control-system) )
74. INSTALL AIR CLEANER INLET ASSEMBLY Install the air cleaner inlet with the clamp and 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
75. CONNECT VACUUM HOSES
76. INSTALL V-RIBBED BELT (See «INSTALLATION»(ref-283093-S36814178942008041700000) )
77. INSTALL FRONT WHEELS Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
78. Add ENGINE OIL
79. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
80. ADD ENGINE COOLANT (See «ON-VEHICLE INSPECTION»(/lexus/es/xv40-2006-2009/remont/cooling-fan/#engine-cooling-system) )
81. ADD AUTOMATIC TRANSAXLE FLUID HINT: See «AUTOMATIC TRANSAXLE FLUId»(/lexus/es/xv40-2006-2009/remont/automatic-trans/#automatic-transaxle-u660e)
82. ADD POWER STEERING FLUID
83. BLEED POWER STEERING FLUID (See «POWER STEERING FLUId»(ref-283113-S28783112142008041700000) )
84. CHECK FOR FUEL LEAKS (See «ON-VEHICLE INSPECTION»(/lexus/es/xv40-2006-2009/remont/fuel-system/#fuel) )
85. INSPECT FOR OIL LEAK
86. INSPECT FOR COOLANT OIL LEAK (See «COOLING SYSTEM»(/lexus/es/xv40-2006-2009/remont/cooling-fan/#engine-cooling-system) )
87. INSPECT FOR EXHAUST GAS LEAK
88. CHECK SHIFT LEVER POSITION (See «ON-VEHICLE INSPECTION»(/lexus/es/xv40-2006-2009/remont/automatic-trans/#automatic-transaxle-u660e) )
89. CHECK AND AdJUST FRONT WHEEL ALIGNMENT HINT: See «FRONT WHEEL ALIGNMENT»(ref-283099-S37688979052008041700000) .
90. CHECK IGNITION TIMING (See «ON-VEHICLE INSPECTION»(ref-283093-S11855719962008041700000) )
91. CHECK ENGINE IDLE SPEED (See «ON-VEHICLE INSPECTION»(ref-283093-S11855719962008041700000) )
92. CHECK CO/HC (See «ON-VEHICLE INSPECTION»(ref-283093-S11855719962008041700000) )
93. CHECK FUNCTION OF THROTTLE BODY (See «ON-VEHICLE INSPECTION»(/lexus/es/xv40-2006-2009/remont/testing-diagnostics/#engine-control-system) )
94. INSTALL FRONT FENDER APRON SEAL RH
95. INSTALL ENGINE UNDER COVER LH
96. INSTALL ENGINE UNDER COVER RH
97. INSTALL V-BANK COVER SUB-ASSEMBLY Fit the 3 retainers and install the V-bank cover.
98. INSTALL ENGINE ROOM SIDE COVER LH Install the engine room side cover LH with the 6 clips. Install the hood hinge cover LH.
99. INSTALL ENGINE ROOM SIDE COVER RH Install the engine room side cover RH with the 5 clips. NOTE: When installing the engine room side cover RH, make sure that the engine coolant reservoir hose is positioned as shown in the illustration. Install the hood hinge cover RH.
100. INSTALL COOL AIR INTAKE DUCT SEAL Install the intake duct seal with the 7 clips.
101. CHECK ABS SPEED SENSOR SIGNAL HINT: See «TEST MODE PROCEDURE»(ref-283114-S12491066992008041700000)
102. PERFORM INITIALIZATION Perform initialization procedure (See «INITIALIZATION»(ref-283083-S29543038892008041700000) ). NOTE: Some systems need initialization after reconnecting the cable to the negative battery terminal.

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

See also:
• ON-VEHICLE INSPECTION
• LUBRICATION SYSTEM
• REMOVAL
• INSTALLATION
• REMOVAL
• REPLACEMENT
• ON-VEHICLE INSPECTION
• REMOVAL