Engine Mechanical (2JZ-GE): Removal & Installation Lexus GS II рестайлинг

REMOVAL & INSTALLATION

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

Removal

Note. Remove engine and transmission as an assembly.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159170-S12660562162003111400000). Disconnect battery cables. Drain cooling system and engine oil. Remove hood. Remove engine undercover. Remove engine cover. Disconnect control cables at throttle body
2. Remove air cleaner inlet, Mass Airflow (MAF) meter and intake air resonator assembly. Disconnect accelerator cable from engine. Remove radiator assembly. Remove drive belt. Remove front suspension member brace. Disconnect necessary electrical wires, cables, straps, connectors, hoses and clamps.
3. Remove ECM hood and cover. Disconnect electrical connectors from ECM. Disconnect wire harness and junction connectors. Disconnect grommet and engine wire from ECM box. Remove power steering pump and A/C compressor with hoses attached, and secure aside.
4. Raise and support vehicle. Disconnect oxygen sensor. Remove 2 bolts and front floor center brace. Disconnect exhaust pipe from "O" rings. Remove 3 bolts, nuts and 2 gaskets from exhaust manifold. Remove bolts and heat insulators.
5. Disconnect electrical connections and control linkages at transmission. Place reference marks on transmission companion flanges and flexible couplings for reassembly reference.
6. Remove companion flange-to-transmission and rear axle companion flange bolts. (Scheme 7) Keep bolts with drive shaft.
7. Remove bolts from center bearing on drive shaft while holding drive shaft in a straight line. Note location of adjusting washers between center bearing and frame (if equipped) for reassembly reference. Push rear drive shaft straight forward to compress drive shaft. Pull drive shaft toward vehicle rear, and remove.
8. Remove transmission control rod. Ensure steering wheel is at straight-ahead position. Place reference marks on sliding yoke and intermediate shaft. Remove bolt holding sliding yoke to steering intermediate shaft. Disconnect power steering pressure switch connector and wire clamp. Remove 4 bolts, and disconnect power steering housing from front frame. Disconnect sliding yoke from intermediate shaft.
9. Support engine with hoist. Remove 2 hole plugs. Remove 4 nuts holding engine mounting insulators to front suspension crossmember. Remove 4 bolts, 4 nuts and rear engine mounting member. Lift engine out of vehicle. Ensure engine is clear of all wiring, hoses and cables.
10. Place engine and transmission on appropriate stand. Disconnect engine wire clamp from dipstick guide. Remove bolt. Pull dipstick guide and dipstick from dipstick tube. Remove "O" ring from dipstick guide. Remove case clamp. Disconnect heated oxygen sensor connector. Remove 8 nuts, exhaust manifold and 2 gaskets. Remove transmission oil cooler pipes.
11. Remove torque converter hole plug. Turn crankshaft pulley bolt to gain access to each bolt. Using wrench, hold crankshaft pulley bolt. Remove 6 torque converter bolts. Remove 4 bolts holding No. 1 oil pan to transmission.
12. Disconnect starter connector. Remove 2 bolts, clamp bracket and starter. Disconnect Vehicle Speed Sensor (VSS), Park Neutral Position (PNP) switch, solenoid and direct clutch speed sensor connectors from transmission. Disconnect engine wire from 3 wire clamps. Remove 5 bolts and ground wire. Remove transmission with torque converter clutch from engine. Remove 8 bolts, rear and drive plates, and front spacer.

Scheme 7

Installation

1. To install, reverse removal procedure. Ensure transmission crossmember is installed with front mark (L6) facing front of vehicle. Front mark is stamped on top of crossmember and should be positioned on driver's side of vehicle. Ensure front mark is facing upward (toward body).
2. Before installing drive shaft, apply grease to center bushing located in companion flange. Ensure reference marks on drive shaft companion flanges are aligned.
3. Install NEW nuts when installing exhaust pipe components. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-159170-S19795112022003111400000) . Adjust fluid levels, control cables and shift linkage (if necessary).

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159170-S12660562162003111400000). Disconnect negative battery cable. Remove air intake hose assembly with airflow meter and air cleaner. Drain cooling system.
2. Remove drive belt. Disconnect power steering air hoses from No. 4 timing belt cover and air intake chamber. Remove 2 bolts and pump rear stay. Remove 2 bolts, and disconnect vane pump from pump bracket.
3. Disconnect front exhaust pipe from exhaust manifold. Disconnect 3 heated oxygen sensor connectors. Remove clamps and case clamp. Using 14 mm deep socket wrench, remove 8 nuts, exhaust manifold and 2 gaskets.
4. Remove water by-pass outlet and No. 1 water by-pass pipe. Remove throttle body and intake air assembly. Remove oil dipstick and guide. Remove air intake chamber. Disconnect VSV connector for Air Control Intake Sensor (ACIS). Remove 3 nuts, vacuum control valve set and No. 2 vacuum pipe.
5. Remove No. 3 timing belt cover. Remove ignition coils and spark plug cord set assembly. Remove spark plugs. Disconnect ground strap from cylinder head. Disconnect 2 water by-pass hoses from hose clamps on cylinder head and oil filter bracket.
6. Disconnect bank 2 heated oxygen sensor connector from hose clamp. Remove 2 bolts and hose clamps. Disconnect bank 1 heated oxygen sensor. Disconnect crankshaft position sensor connector. Remove bolt and clamp bracket, and disconnect engine wire from water pump.
7. Disconnect 2 ground terminals and wire clamps from intake manifold. Remove 2 bolts and clamp brackets. Disconnect necessary electrical connectors for intake manifold removal.
8. Using 5-mm hexagon wrench, remove bolt holding engine wire protector to No. 2 cylinder head cover. Remove nuts, and disconnect engine wire protector from intake manifold. Remove fuel pressure pulsation damper.
9. Disconnect starter wire from manifold stay. Remove nuts, bolts, manifold stay, intake manifold stay, delivery pipe assembly and gasket. Disconnect timing belt from camshaft timing pulleys.
10. Remove exhaust camshaft timing pulley. Using wrench, hold hexagon portion of camshaft, and remove pulley bolt and camshaft pulley. Remove No. 4 timing belt cover. (Scheme 8) Loosen and remove No. 1 and No. 3 camshaft bearing cap bolts. Using screwdriver, pry out No. 1 and No. 3 camshaft bearing caps and oil seals. CAUTION: Camshaft bearing cap bolts must be removed in proper sequence to prevent damage to cylinder head and camshaft thrust surfaces.
11. Remove camshaft bearing cap bolts in sequence using several steps. (Scheme 9) Remove camshaft bearing caps and camshaft. Note location of adjusting shims and valve lifters. Remove adjusting shims and valve lifters from cylinder head (if necessary). CAUTION: Loosen cylinder head bolts in proper sequence to prevent cylinder head warpage.
12. Loosen cylinder head bolts in sequence using several steps. (Scheme 10) Remove cylinder head bolts, cylinder head and cylinder head gasket.

Note. If cylinder head removal is difficult, carefully pry between cylinder head and projected area near front of cylinder block. DO NOT damage sealing surfaces on cylinder block and cylinder head.

Scheme 8

Scheme 9

Scheme 10

1. Install cylinder head. Apply light coat of oil to threads and underside of cylinder head bolts. Install cylinder head bolts and tighten to specification in sequence using several steps. (Scheme 10) See «TORQUE SPECIFICATIONS»(ref-159170-S19795112022003111400000).
2. Install camshafts. See «CAMSHAFT»(ref-159170-S06415923672003111400000). Check and adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(ref-159170-S16808540372003111400000) under ADJUSTMENTS. Install No. 4 timing belt cover.
3. To install remaining components, reverse removal procedure using NEW gaskets and "O" rings. Use NEW nuts when installing exhaust manifold. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159170-S19795112022003111400000).
4. Before installing gaskets and valve covers, apply sealant at indicated areas on front of cylinder head. see scheme 6 Install intake manifold and delivery pipe assembly with 7 bolts and 2 nuts. Pass water by-pass hose between No. 2 and No. 3 intake ports of manifold and delivery pipe. Install manifold stay and bolts. Install starter wire to manifold stay. Install fuel pressure pulsation damper.
5. Install engine wire protector with 4 nuts. Using 5-mm hexagon wrench, install bolt holding engine wire protector to No. 2 cylinder head cover. Connect necessary electronic and injector connectors. Install clamp bracket, and connect wire clamps on intake manifold.
6. Install 2 ground terminals to intake manifold. Install clamp bracket to water pump. Connect crankshaft position sensor and oxygen sensor (bank 1 sensor 1) connectors. Install hose clamps to cylinder head and oil filter bracket. Install oxygen sensor (bank 2 sensor 1) connector. Install ground strap to cylinder head.
7. To install remaining components, reverse removal procedure. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159170-S19795112022003111400000).

Removal & Installation (Oil Pump Installed)

1. Remove timing belt and crankshaft sprocket. See «TIMING BELT REPLACEMENT - 3.0L 6-CYLINDER»(ref-156554) article in ENGINE. Using a knife, cut seal lip from seal. Carefully pry seal from oil pump body. Use care not to damage sealing surfaces.
2. To install, apply grease to sealing lip of seal. Using hammer and Seal Installer (SST 09316-60011), install seal until seal surface is even with oil pump body. To install remaining components, reverse removal procedure.

Removal & Installation (Oil Pump Removed)

Pry seal from oil pump body. Using hammer and Seal Installer (SST 09316-60011), install seal until seal surface is even with oil pump body. Apply grease to sealing lip of seal.

Remove camshaft. See CAMSHAFT . Note location of adjusting shims and valve lifters for installation 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 shims or valve lifters are replaced, check valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159170-S12660562162003111400000). Disconnect negative battery cable. Remove air intake hose assembly with airflow meter and air cleaner. Drain cooling system.
2. Remove drive belt. Disconnect power steering air hoses from No. 4 timing belt cover and air intake chamber. Remove 2 bolts and pump rear stay. Remove 2 bolts, and disconnect vane pump from pump bracket.
3. Disconnect front exhaust pipe from exhaust manifold. Disconnect 3 heated oxygen sensor connectors. Remove clamps and case clamp. Using 14-mm deep socket wrench, remove nuts, exhaust manifold and gaskets.
4. Remove water by-pass outlet and No. 1 water by-pass pipe. Remove throttle body and intake air assembly. Remove oil dipstick and guide. Remove air intake chamber. Disconnect VSV connector for Air Control Intake Sensor (ACIS). Remove 3 nuts, vacuum control valve set and No. 2 vacuum pipe.
5. Remove No. 3 timing belt cover. Remove ignition coils and high-tension cord set assembly. Remove spark plugs. Disconnect ground strap from cylinder head. Disconnect 2 water by-pass hoses from hose clamps on cylinder head and oil filter bracket.
6. Disconnect bank 2 heated oxygen sensor connector from hose clamp. Remove 2 bolts and hose clamps. Disconnect bank 1 heated oxygen sensor. Disconnect crankshaft position sensor connector. Remove bolt and clamp bracket, and disconnect engine wire from water pump.
7. Disconnect 2 ground terminals and wire clamps from intake manifold. Remove bolts and clamp brackets. Disconnect necessary electrical connectors for intake manifold removal.
8. Using 5-mm hexagon wrench, remove bolt holding engine wire protector to No. 2 cylinder head cover. Remove nuts, and disconnect engine wire protector from intake manifold. Remove fuel pressure pulsation damper.
9. Disconnect starter wire from manifold stay. Remove nuts, bolts, manifold stay, intake manifold stay, delivery pipe assembly and gasket. Remove cylinder head valve covers. Disconnect timing belt from camshaft timing pulleys. Hold hexagon portion of exhaust camshaft with wrench and remove sprocket. Remove No. 4 timing belt cover.
10. Using 5-mm hexagon wrench, remove No. 1 and No. 3 camshaft bearing cap bolts. (Scheme 8) Using screwdriver, carefully pry No. 1 and No. 3 camshaft bearing caps upward from cylinder head and remove. DO NOT damage sealing surfaces. Remove oil seals from camshaft.
11. Remove camshaft bearing cap bolts in sequence using several steps. (Scheme 9) Remove camshaft bearing caps and camshaft. Note location of adjusting shims and valve lifters. Remove adjusting shims and valve lifters from cylinder head (if necessary).

1. Install valve lifters and adjusting shims in original location (if removed). Apply engine oil to camshaft journals and thrust surfaces. Install camshaft in cylinder head with camshaft dowel pins properly positioned and specified lobes facing upward. (Scheme 11)
2. Install No. 3 and 7 camshaft bearing caps. Ensure camshaft bearing caps are installed in correct positions. (Scheme 12) Coat all camshaft bearing cap bolt threads and bolt-to-camshaft bearing cap surface with engine oil.
3. Install camshaft bearing cap bolts in No. 3 and 7 camshaft bearing caps. Alternately tighten No. 3 and 7 camshaft bearing cap bolts until snug.
4. Coat lip of NEW oil seal with grease and install on front edge of camshaft. Apply sealant on No. 1 and No. 3 camshaft bearing caps at bearing cap-to-cylinder head surface, and install No. 1 and No. 3 bearing cap. Install all remaining camshaft bearing caps.
5. Install and tighten all camshaft bearing cap bolts in sequence until snug. (Scheme 9)
6. Using Oil Seal Installer (SST 09316-60011), push in oil seals as far as possible. Using wrench on hexagonal area of camshaft, rotate camshafts until camshaft dowel pin is at 12 o'clock position.
7. Loosen camshaft bearing cap bolts on designated camshaft bearing caps until bolts can be turned by hand. Perform step 1) in illustration. (Scheme 12) Retighten camshaft bearing cap bolts evenly to specification using several steps. See «TORQUE SPECIFICATIONS»(ref-159170-S19795112022003111400000).
8. Rotate camshafts clockwise until camshaft dowel pin moves an additional 1/3 turn (120 degrees). Loosen camshaft bearing cap bolts on designated camshaft bearing caps until bolts can be turned by hand. Perform step 2) in illustration. (Scheme 12) Retighten camshaft bearing cap bolts evenly to specification using several steps.
9. Rotate camshafts clockwise until camshaft dowel pin moves an additional 1/3 turn (120 degrees). Loosen camshaft bearing cap bolts on designated camshaft bearing caps until bolts can be turned by hand. Perform step 3) in illustration. (Scheme 12) Retighten camshaft bearing cap bolts evenly to specification using several steps.
10. Check and adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(ref-159170-S16808540372003111400000) under ADJUSTMENTS. Install No. 4 timing belt cover. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159170-S19795112022003111400000). Install camshaft sprockets and timing belt.
11. To install remaining components, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-159170-S19795112022003111400000). Before installing gaskets and valve covers, apply sealant to valve cover sealing areas on front of cylinder head. see scheme 6
12. Ensure air intake connector gasket is installed with protrusion in proper location.

Scheme 11

Scheme 12

Remove transmission and flywheel/drive plate. Using a knife, cut off seal lip. Carefully pry oil seal from rear oil seal housing. DO NOT damage sealing surfaces.

1. Ensure all sealing surfaces are clean. Apply grease to seal lip of new oil seal. Using Oil Seal Installer (SST 09223-15030) and Handle (SST 09951-07100), install oil seal in rear oil seal housing until even with housing surface.
2. Apply Loctite to flywheel/drive plate bolts. Install and tighten flywheel/drive plate bolts to specification in a crisscross pattern. See «TORQUE SPECIFICATIONS»(ref-159170-S19795112022003111400000) . To install remaining components, reverse removal procedure.

1. Disconnect negative battery cable. Remove radiator. Remove drive belt, fan coupling and water pump pulley. Remove timing belt and idler pulley. See «TIMING BELT REPLACEMENT - 3.0L 6-CYLINDER»(ref-156554) article in ENGINE. Remove 2 bolts, water by-pass outlet and by-pass pipe. Remove water inlet, lower radiator hose and thermostat housing.
2. Loosen nut and remove bolt from generator mounting, and slide generator off water pump. Disconnect clamp bracket for crankshaft position sensor. Remove water by-pass pipe from water pump. Remove bolts, water pump and gasket. Remove "O" ring from cylinder block.

1. Install NEW "O" ring to cylinder block. Apply soapy water to "O" ring. Connect water pump to water by-pass pipe end.
2. Install water pump bolts. Ensure correct bolt is installed in specified location. Hand tighten bolts "A". (Scheme 13) Install nuts holding water by-pass pipe to water pump. Tighten all water pump bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159170-S19795112022003111400000).
3. To complete installation, reverse removal procedure. Fill engine with coolant. Check for leaks.

Scheme 13

1. Remove engine. See «ENGINE»(ref-159170-S26270096002003111400000). Remove crankshaft position sensor. Remove timing belt. See «TIMING BELT REPLACEMENT - 3.0L 6-CYLINDER»(ref-156554) article in ENGINE. Remove dipstick, bolt, dipstick tube and "O" ring. Remove bolts, oil level sensor and gasket. (Scheme 14)
2. Remove No. 2 oil pan bolts and nuts. Install Seal Cutter (SST 09032-00100) between No. 1 and 2 oil pans. Tap seal cutter around No. 2 oil pan to loosen seal. Remove No. 2 oil pan. DO NOT damage sealing surfaces.
3. Remove oil strainer. Remove oil pan baffle plate. (Scheme 14) Note location of No. 1 oil pan bolts. Remove bolts, No. 1 oil pan and "O" ring from cylinder block.

To install, reverse removal procedure. Ensure sealing surfaces are clean. Apply a.16-.19 in. (4.0-5.0 mm) diameter bead of sealant at designated areas on oil pans. (Scheme 14)or (Scheme 15). Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS.

Scheme 14

Scheme 15

Removal & Disassembly

1. Remove engine. See «ENGINE»(ref-159170-S26270096002003111400000) under REMOVAL & INSTALLATION. Remove crankshaft position sensor. Remove timing belt, idler pulley and crankshaft sprocket. See «TIMING BELT REPLACEMENT - 3.0L 6-CYLINDER»(ref-156554) article in ENGINE.
2. Remove oil pan. See «OIL PAN»(ref-159170-S29343352882003111400000) under REMOVAL & INSTALLATION. Remove oil pump bolts. Using hammer and brass bar, tap oil pump body, then remove oil pump. Remove "O" rings from cylinder block.
3. Remove relief valve plug, gasket, spring and relief valve. (Scheme 16) Remove screws, oil pump cover and rotors. Remove crankshaft front seal (if necessary).

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure drive and driven rotors are installed in oil pump body with reference mark (triangle mark) toward oil pump cover. Tighten oil pump cover bolts and relief valve plug to specification. See «TORQUE SPECIFICATIONS»(ref-159170-S19795112022003111400000) .
2. To install, ensure sealing surfaces are clean. Install NEW "O" rings on cylinder block. Apply sealant on oil pump body. CAUTION: Ensure sealant does not enter oil passages on oil pump body.
3. Install oil pump and bolts. Ensure 2 long bolts are installed in 2 lower bolt holes on intake manifold side of cylinder block. Tighten oil pump bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159170-S19795112022003111400000) .
4. If installing crankshaft front seal, use hammer and seal installer. Install seal until seal surface is even with oil pump body. Apply grease to sealing lip of seal. To install remaining components, reverse removal procedure.

Scheme 16