Engine Mechanical (Service Information): Overview Lexus GS III рестайлинг

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1. 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 perform the inspection above again. If any defects or problems are found during the inspection above, perform a lash adjuster inspection.
2. INSPECT IGNITION TIMING Warm up and stop the engine. NOTE: A warmed up engine should have an engine coolant temperature of over 80°C (176°F) and an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized. When using the Techstream: Connect the Techstream to the DLC3. Start the engine and idle it. Push the Techstream main switch ON. Enter the following items: Powertrain / Engine and ECT / Data List / IGN Advance. Standard ignition timing 8 to 18° BTDC at idle HINT: Refer to the Techstream operator's manual for further details. When not using the Techstream: Remove the V-bank cover. Connect the tester probe of a timing light to the wire of the ignition connector for No. 1 cylinder. NOTE: Use a timing light which can detect the primary current. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. SST: 09843-18040 NOTE: Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine. When checking the ignition timing, the transmission should be in neutral. Using a timing light, check the ignition timing. Standard ignition timing 8 to 12° BTDC at idle Remove the SST from the DLC3. Check the ignition timing. Standard ignition timing 8 to 18° BTDC at idle Check that the ignition timing advances immediately when the engine speed is increased. Disconnect the timing light from the engine. Install the V-bank cover.
3. INSPECT ENGINE IDLE SPEED Warm up and stop the engine. NOTE: A warmed up engine should have an engine coolant temperature of over 80°C (176°F) and an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized. When using the Techstream: Connect the Techstream to the DLC3. NOTE: Switch off all accessories and A/C before connecting the Techstream. Race the engine speed at 2,500 rpm for approximately 90 seconds. Push the Techstream main switch ON. Enter the following items: Powertrain / Engine and ECT / Data List / Engine Speed. Standard idle speed 950 to 1,050 rpm NOTE: When checking the idle speed, the transmission should be in the neutral. HINT: Refer to the Techstream operator's manual for further details. If the idle speed is not as specified, check the air intake system. Disconnect the Techstream from the DLC3. When not using the Techstream: Using SST, connect the tachometer probe to terminal 9 (TAC) of the DLC3. SST: 09843-18040 NOTE: Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine. Race the engine speed at 2,500 rpm for approximately 90 seconds. Check the idle speed. Idle speed (Transmission neutral position) 950 to 1,050rpm If the speed is not as specified, check the air intake system. Disconnect the tachometer from the DLC3.
4. INSPECT COMPRESSION Warm up and stop the engine. NOTE: A warmed up engine should have an engine coolant temperature of over 80°C (176°F) and an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized. Remove the cool air intake duct seal. Remove the engine room side cover LH. Remove the engine room side cover RH. Remove the V-bank cover. Disconnect the No. 2 ventilation hose. Remove the air cleaner cap with the air cleaner hose. Remove the nut. Detach the protector from the bracket. Remove the 2 nuts and inverter motor cable bracket. Remove the bolt and water filler. Remove the clamp and plug. Disconnect the 3 clamps and connector. Disconnect the 4 connectors. Disconnect the throttle body connector. Disconnect the 6 injector connectors. Remove the 6 ignition coils. Remove the 6 spark plugs. Disconnect the 2 injector driver connectors as shown in the illustration. Inspect the compression pressure. Insert a compression gauge into the spark plug hole. Connect the Techstream to the DLC3. Turn the power switch ON (IG). Push the Techstream main switch ON. To check the battery voltage, enter the following items: Powertrain / Hybrid Control / Data List / +B. Standard voltage 10 to 14 V Enter the following items: Powertrain / Hybrid Control / Active Test / Compression Test. Depress and hold the brake pedal, and turn the power switch ON (READY). Then check the compression pressure. HINT: Noise may emit from the transmission. However, this is not a malfunction. Always use a fully charged battery to obtain engine speed of 200 rpm or more. NOTE: The measurement must be done as quickly as possible. Standard compression pressure 1.0 MPa (10 kgf/cm 2 , 143 psi) or more Minimum pressure 0.7 MPa (7.1 kgf/cm 2 , 101 psi) Turn the power switch OFF and the Techstream main switch off. Perform the following inspection procedures for the other cylinders. HINT: Make sure to turn the power switch OFF and the Techstream main switch off between each pressure inspection. If not, the compression pressure cannot be inspected. Insert a compression gauge into the spark plug hole. Turn the power switch ON (IG). Push the Techstream main switch on. Enter the following items: Powertrain / Hybrid Control / Active Test / Compression Test. Depress and hold the brake pedal, and turn the power switch ON (READY). Then check the compression pressure. HINT: Noise may emit from the transmission. However, this is not a malfunction. Always use a fully charged battery to obtain engine speed of 200 rpm or more. NOTE: The measurement must be done as quickly as possible. Standard compression pressure 1.0 MPa (10 kgf/cm 2 , 143 psi) or more Minimum compression pressure 0.7 MPa (7.1 kgf/cm 2 , 101 psi) Turn the power switch OFF and the Techstream main switch off. Check the pressure difference between each compression pressure. Pressure difference 0.1 MPa (1.0 kgf/cm 2 , 15 psi) or less If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder through the spark plug hole. Then perform the first 3 steps under "inspect the cylinder compression pressure" for the cylinders with low compression. HINT: If adding oil helps boost the compression, it is likely that the piston rings and/or cylinder bore are worn or damaged. If pressure stays low, a valve may be stuck or seated improperly, or there may be leakage in the gasket. Connect the 2 injector driver connectors as shown in the illustration. 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) Connect the 6 injector connectors. Connect the throttle body connector. Connect the 4 connectors. Connect the 3 clamps and connector. Install the clamp and plug. Install the water filler with the bolt. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) Install the inverter motor cable bracket with the 2 nuts. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) Attach the protector to the bracket. Install the nut. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) Install the air cleaner cap with the air cleaner hose. Connect the No. 2 ventilation hose. Install the V-bank cover. Install the engine room side cover LH. Install the engine room side cover RH. Install the cool air intake duct seal.
5. INSPECT CO/HC HINT: This check for determines whether or not the idle CO / HC complies with regulations. Start the engine. Keep the engine speed 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. Immediately check CO / HC concentration at idle and 2,500 rpm. HINT: When performing the 2 mode (2,500 rpm and idle) test, follow the measurement order prescribed by the applicable local regulations. If the CO / HC concentration does not comply with regulations, troubleshoot in the order given below. Check the A/F sensor and heated oxygen sensor operation. See the table below for possible causes, then inspect and correct the applicable causes if necessary. CO HC Symptom Causes Normal High Rough idle 1 . Faulty ignitions Incorrect timing Plugs are contaminated, shorted, or gaps are defective. 2. Leaky intake and exhaust valves 3. Leaky cylinder Low High Rough idle (Fluctuating HC reading) 1. Vacuum leaks PCV hose Intake manifold Throttle body 2. Lean mixture causing misfire High High Rough idle (Black smoke from exhaust) 1. Restricted air filter 2. Faulty SFI system Faulty pressure Defective ECT sensor Faulty ECM Faulty injector Faulty throttle position sensor Faulty MAF sensor

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1. CHECK FAN & GENERATOR V BELT Check the belt for wear, cracks or other signs of damage. If any of the following defects is found, replace the V-ribbed belt. The belt is cracked. The belt is worn out to the extent that the cords are exposed. The belt has chunks missing from the ribs. Check that the belt fits properly in the ribbed grooves. HINT: Check with your hand to confirm that the belt has not slipped out of the grooves on the bottom of the pulley. If it has slipped out, replace the V-ribbed belt. Install a new V-ribbed belt correctly.

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1. REMOVE COOL AIR INTAKE DUCT SEAL See step 10
2. REMOVE NO. 1 AIR CLEANER INLET Remove the bolt and air cleaner inlet.
3. REMOVE FAN & GENERATOR V BELT Rotate the tensioner pulley counterclockwise to loosen the belt tension. Then remove the V belt. NOTE: The pulley bolt for the belt tensioner has a left-handed thread. Do not perform this procedure from underneath the vehicle, as the tensioner may be damaged.

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1. INSTALL FAN & GENERATOR V BELT Rotate the tensioner pulley counterclockwise, and then install the V belt as shown in the illustration. NOTE: Check that the drive belt is properly set to each pulley.
2. INSTALL NO. 1 AIR CLEANER INLET Install the air cleaner inlet with the bolt. Torque: 5.0 N*m ( 51 kgf*cm, 44 in.*lbf)
3. INSTALL COOL AIR INTAKE DUCT SEAL See step 100

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1. REMOVE INVERTER WITH CONVERTER ASSEMBLY Refer to «REMOVAL»(ref-387078-S11513422702011022400000) .
2. REMOVE ECM HINT: Refer to «REMOVAL»(ref-387086-S06388950852011022400000) .
3. REMOVE FUEL PUMP ASSEMBLY Refer to «REMOVAL»(ref-387088-S13301118782011022400000) .
4. REMOVE SKID CONTROL ECU Refer to «REMOVAL»(ref-386953-S26247972342011022400000) .
5. REMOVE WATER FILLER ASSEMBLY Disconnect the 2 hoses from water filler assembly. Remove the 2 bolts and water filler assembly.
6. REMOVE NO. 1 ENGINE COVER See step 62
7. REMOVE INJECTOR DRIVER See step 69
8. REMOVE IGNITION COIL ASSEMBLY . Refer to «REMOVAL - Step 9»(/lexus/gs/iii-2007-2011/remont/ignition-system/#ignition-service-information)
9. REMOVE SPARK PLUG
10. REMOVE NO. 1 OIL PIPE Disconnect the connectors. Remove the oil check valve bolt, oil pipe union and oil pipe. Remove the oil control valve filter LH and gaskets.
11. REMOVE NO. 2 OIL PIPE See step 8
12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH HINT: Make sure the cylinder head cover is clear of all wiring and connectors. Make sure the removed parts are returned to the same places they were removed from. Remove the 12 bolts, head cover sub-assembly LH and gasket. TEXT IN ILLUSTRATION *1 Baffle Plate NOTE: The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the head cover. Remove the 3 gaskets.
13. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY HINT: Make sure the cylinder head cover is clear of all wiring and connectors. Make sure the removed parts are returned to the same places they were removed from. Remove the 14 bolts, cylinder head cover sub-assembly and gasket. Remove the 3 gaskets.
14. REMOVE TIMING CHAIN COVER PLATE Remove the 4 bolts, timing chain cover plate and gasket.
15. SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley and align the notch with the "0" timing mark of the timing chain cover. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration. TEXT IN ILLUSTRATION *A for Bank 2 *B for Bank 1 *1 Paint Mark *2 Timing Mark HINT: If the marks are not aligned, turn the crankshaft again to align the marks. Place paint marks on the chain in alignment with the timing marks on each camshaft timing gear and bearing cap. HINT: Be sure to place the paint marks on 2 links of the chain and on the sprockets of the camshaft timing gears at the locations of the timing marks of the camshaft timing gears.
16. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY Turn the crankshaft approximately 30° counterclockwise so that there is some slack in the chain. HINT: This prevents the valves and pistons from interfering with each other. Align the hole in the lever of the tensioner with the hole in the tensioner body as shown in the illustration, and then insert a pin with a diameter of 1.27 mm (0.0500 in.) into the hole. TEXT IN ILLUSTRATION *1 Lever Hole *2 Tensioner Hole Turn the crankshaft clockwise and align the notch with the "0" timing mark of the timing chain cover. Remove the 2 bolts and chain tensioner. NOTE: Do not drop the No. 1 chain tensioner assembly or bolts into the timing chain cover.
17. SEPARATE CHAIN SUB-ASSEMBLY Turn the crankshaft clockwise until it is in the position shown in the illustration so that there is some slack in the chain between the banks. WARNING: As the camshafts turn suddenly, do not touch the camshafts or camshaft timing gears. HINT: When turning the crankshaft, engine oil may spray out of the oil holes. Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain can be removed easily. HINT: When turning the crankshaft, engine oil may spray out of the oil holes. Remove the chain from the sprocket of the camshaft timing gear and set it on the camshaft timing gear. WARNING: As the camshaft may turn suddenly and pinch your fingers when the chain is removed, pinch the chain and lift it upward to remove it from the sprocket.
18. REMOVE CAMSHAFT BEARING CAP (for Bank 1) Remove the bolts and bearing caps in the order shown in the illustration. Immediately after removing bearing caps, install service bolts and washers in the order shown in the illustration. TEXT IN ILLUSTRATION *1 Service Bolt and Washers (used to temporarily secure the camshaft housing) *a Part to be removed *b Install the service bolts and washers to temporarily secure the camshaft housing Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) HINT: Arrange the removed parts so that they can be reinstalled in their original locations. Part number for the service bolts used to temporarily secure the camshaft housing: 91551-G0845 (9 bolts) Part number for the service washers used to temporarily secure the camshaft housing: 90201-12028 (18 washers) NOTE: Do not install the bearing caps when installing the service bolts and washers. Be sure to follow the numerical order when performing this procedure. Do not allow the service bolts and washers to contact the camshaft. Do not drop the service bolts and washers into the cylinder head.
19. REMOVE NO. 2 CAMSHAFT Remove the bolt of the No. 2 chain tensioner assembly. Remove the No. 2 chain tensioner assembly while lifting up the No. 2 camshaft. While lifting up the No. 2 camshaft, pass it through the No. 2 chain and pull it out towards the front of the vehicle to remove it.
20. REMOVE CAMSHAFT Lift up the rear of the camshaft so that it is at an angle. Remove the chain from the camshaft timing gear and pull out the camshaft and No. 2 chain towards the rear of the vehicle to remove them. NOTE: Do not drop the chain into the gap between the engine and cover. Suspend the chain with a string or equivalent.
21. SEPARATE CHAIN SUB-ASSEMBLY Turn the crankshaft counterclockwise and align the notch with the "0" timing mark of the timing chain cover. Remove the chain from the sprocket of the camshaft timing gear and set it on the camshaft timing gear. WARNING: As the camshaft may turn suddenly and pinch your fingers when the chain is removed, pinch the chain and lift it upward to remove it from the sprocket.
22. REMOVE CAMSHAFT BEARING CAP (for Bank 2) Remove the bolts and bearing caps in the order shown in the illustration. Immediately after removing bearing caps, install service bolts and washers in the order shown in the illustration. TEXT IN ILLUSTRATION *1 Service Bolt and Washers (used to temporarily secure the camshaft housing) *a Part to be removed *b Install the service bolts and washers to temporarily secure the camshaft housing Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) HINT: Arrange the removed parts so that they can be reinstalled in their original locations. Part number for the service bolts used to temporarily secure the camshaft housing: 91551-G0845 (8 bolts) Part number for the service washers used to temporarily secure the camshaft housing: 90201-12028 (16 washers) NOTE: Do not install the bearing caps when installing the service bolts and washers. Be sure to follow the numerical order when performing this procedure. Do not allow the service bolts and washers to contact the camshaft. Do not drop the service bolts and washers into the cylinder head.
23. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY Remove the bolt of the No. 3 chain tensioner assembly. Remove the No. 3 chain tensioner assembly while lifting up the No. 4 camshaft. While lifting up the No. 4 camshaft, pass it through the No. 2 chain and pull it out towards the front of the vehicle to remove it.
24. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY Lift up the rear of the camshaft so that it is at an angle. Remove the chain from the camshaft timing gear and pull out the No. 3 camshaft and No. 2 chain towards the rear of the vehicle to remove them. NOTE: Do not drop the chain into the gap between the engine and cover. Suspend the chain with a string or equivalent.
25. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY Check the lock of the camshaft timing gear assembly. Clamp the camshaft in a vise, and confirm that the camshaft timing gear assembly is locked. NOTE: Be careful not to damage the camshaft. Release the lock pin. TEXT IN ILLUSTRATION *1 Advanced Side Path *2 Retard Side Path *3 Open *4 Close *5 Rubber *6 Vinyl Tape Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 28 psi) of air pressure to the 2 opened paths. TEXT IN ILLUSTRATION *1 Advanced Side Path *2 Retard Side Path WARNING: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying. Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path. TEXT IN ILLUSTRATION *1 Advance Side Path *2 Retard Side Path *3 Hold Pressure *4 Decompress HINT: This operation releases the lock pin at the most retarded position. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from the advance side path. NOTE: Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin. Check for smooth rotation. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly. NOTE: Do not use air pressure to perform the smooth operation check. Check the lock in the most retarded position. Confirm that the camshaft timing gear assembly locks at the most retarded position. Remove the flange bolt and camshaft timing gear assembly. TEXT IN ILLUSTRATION *1 Do Not Remove *2 Straight Pin *3 Flange Bolt NOTE: Do not remove the other 3 bolts. If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.
26. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Check the camshaft timing exhaust gear lock. Make sure that the camshaft timing exhaust gear assembly locks. Release the lock pin. TEXT IN ILLUSTRATION *1 Advanced Side Path *2 Retard Side Path *3 Open *4 Close *5 Rubber *6 Vinyl Tape Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. HINT: The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration. Apply approximately 200 kPa (2.0 kgf/cm 2 , 28 psi) of air pressure to the 2 opened paths (the advance side path and the retard side path). TEXT IN ILLUSTRATION *1 Advanced Side Path *2 Retard Side Path WARNING: Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying. Make sure that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path. TEXT IN ILLUSTRATION *1 Advance Side Path *2 Retard Side Path *3 Hold Pressure *4 Decompress HINT: The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure first from the advance side path, and then release the air pressure from the retard side path. NOTE: Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts. Check for smooth rotation. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear assembly turns smoothly. NOTE: When the air pressure is released from the advance side path and then from the retard side path, the gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check. Check the lock at the most advanced position. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position. Remove the flange bolt and camshaft timing exhaust gear assembly. TEXT IN ILLUSTRATION *1 Do Not Remove *2 Straight Pin *3 Flange Bolt NOTE: Be sure not to remove the other 4 bolts. If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

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1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY Clamp the camshaft in a vise. NOTE: Be careful not to damage the camshaft in the vise. Put the camshaft timing gear assembly and camshaft together by aligning the pin hole and straight pin. TEXT IN ILLUSTRATION *1 Pin Hole *2 Straight Pin Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole. NOTE: Be sure not to turn the camshaft timing gear assembly in the retard direction. Check that there is no clearance between the camshaft timing gear assembly flange and camshaft. Install the flange bolt while holding the camshaft. Torque: 100 N*m ( 1020 kgf*cm, 74 ft.*lbf) Check the lock of the camshaft timing gear assembly. Secure the camshaft in place and confirm that the camshaft timing gear assembly is locked. NOTE: Be careful not to damage the camshaft.
2. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY Clamp the camshaft in a vise. NOTE: Be careful not to damage the camshaft in the vise. Put the camshaft timing exhaust gear assembly and camshaft together by aligning the pin hole and straight pin. TEXT IN ILLUSTRATION *1 Pin Hole *2 Straight Pin Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole. NOTE: Be sure not to turn the camshaft timing exhaust gear in the advanced direction. Check that there is no clearance between the gear flange and camshaft. Install the flange bolt while holding the camshaft. Torque: 100 N*m ( 1020 kgf*cm, 74 ft.*lbf) Check the camshaft timing exhaust gear lock. Make sure that the camshaft timing exhaust gear assembly locks.
3. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY Check that the notch is aligned with the "0" timing mark of the timing chain cover. Align the mark plate (yellow) with the timing mark of the camshaft timing gear as shown in the illustration and install the No. 2 chain to the camshaft timing gear. TEXT IN ILLUSTRATION *1 Timing Mark *2 Mark Plate (yellow) *a Align Clean the camshaft housing LH and camshaft journals, and apply engine oil to them. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap Install the chain to the No. 3 camshaft, and then install the camshaft to the camshaft housing LH. TEXT IN ILLUSTRATION *a Place on camshaft timing gear HINT: Place the chain on the camshaft timing gear but do not engage the teeth of the sprocket and the chain. Install the camshaft so that the timing mark is facing upward.
4. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY Clean the camshaft housing LH and camshaft journals, and apply engine oil to them. Pass the No. 4 camshaft through the No. 2 chain from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain to the camshaft timing exhaust gear. TEXT IN ILLUSTRATION *1 Mark Plate (yellow) *2 Timing Mark While lifting up the No. 4 camshaft, pass the No. 3 chain tensioner assembly through the No. 2 chain and set it in place. Install the No. 4 camshaft to the camshaft housing LH, and then install the No. 3 chain tensioner assembly with the bolt. Torque: 21 N*m ( 214 kgf*cm, 15 ft.*lbf)
5. INSTALL CAMSHAFT BEARING CAP (for Bank 2) Clean the camshaft bearing caps and apply engine oil to them. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap Check the marks and numbers on the camshaft bearing caps, and then remove the service bolts and washers in the order shown in the illustration. Immediately after removing the service bolts and washers in the location for bearing caps, install the bearing caps with the bolts in the order shown in the illustration. for Bolt A Torque: 28 N*m ( 286 kgf*cm, 21 ft.*lbf) for Bolt B Torque: 16 N*m ( 163 kgf*cm, 12 ft.*lbf) TEXT IN ILLUSTRATION *1 Service Bolts and Washers (used to temporarily secure the camshaft housing) *a Remove the service bolts and washers used to temporarily secure the camshaft housing *b Part to be Installed Bolt A Bolt B NOTE: Be sure to follow the numerical order when performing this procedure. Do not drop the service bolts and washers into the cylinder head. Check the torque of each bolt again.
6. INSTALL CHAIN SUB-ASSEMBLY Align the paint marks on the camshaft timing gear and No. 1 chain, and install the No. 1 chain to the camshaft timing gear. TEXT IN ILLUSTRATION *1 Paint Mark HINT: If the paint marks are not aligned, align them by turning the camshaft slightly.
7. INSTALL CAMSHAFT Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain can be installed easily. HINT: When turning the crankshaft, engine oil may spray out of the oil holes. Align the mark plate (yellow) with the timing mark of the camshaft timing gear as shown in the illustration and install the No. 2 chain to the camshaft timing gear. TEXT IN ILLUSTRATION *1 Timing Mark *2 Mark Plate (yellow) *a Align Clean the camshaft housing RH and camshaft journals and apply engine oil to them. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap Install the chain to the camshaft, and then install the camshaft to the camshaft housing RH. TEXT IN ILLUSTRATION *a Place on camshaft timing gear HINT: Place the chain on the camshaft timing gear but do not engage the teeth of the sprocket and the chain. Install the camshaft so that the timing mark is facing upward.
8. INSTALL NO. 2 CAMSHAFT Clean the camshaft housing RH and camshaft journals, and apply engine oil to them. Pass the No. 2 camshaft through the No. 2 chain from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain to the camshaft timing exhaust gear. TEXT IN ILLUSTRATION *1 Mark Plate (yellow) *2 Timing Mark While lifting up the No. 2 camshaft, pass the No. 2 chain tensioner assembly through the No. 2 chain and set it in place. Install the No. 2 camshaft to the camshaft housing RH, and then install the No. 2 chain tensioner assembly with the bolt. Torque: 21 N*m ( 214 kgf*cm, 15 ft.*lbf)
9. INSTALL CAMSHAFT BEARING CAP (for Bank 1) Clean the camshaft bearing caps and apply engine oil to them. Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. TEXT IN ILLUSTRATION *1 Valve Rocker Arm *2 Lash Adjuster *3 Valve Stem *4 Valve Stem Cap Check the marks and numbers on the camshaft bearing caps, and then remove the service bolts and washers in the order shown in the illustration. Immediately after removing the service bolts and washers in the location for bearing caps, install the bearing caps with the bolts in the order shown in the illustration. for Bolt A Torque: 28 N*m ( 286 kgf*cm, 21 ft.*lbf) for Bolt B Torque: 16 N*m ( 163 kgf*cm, 12 ft.*lbf) TEXT IN ILLUSTRATION *1 Service Bolt and Washers (used to temporarily secure the camshaft housing) *a Remove the service bolts and washers to temporarily secure the camshaft housing *b Part to be Installed Bolt A Bolt B NOTE: Be sure to follow the numerical order when performing this procedure. Do not drop the service bolts and washers into the cylinder head. Check the torque of each bolt again.
10. INSTALL CHAIN SUB-ASSEMBLY Align the paint marks on the camshaft timing gear and chain, and install the chain to the camshaft timing gear. TEXT IN ILLUSTRATION *1 Paint Mark HINT: If the paint marks are not aligned, align them by turning the camshaft slightly.
11. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY Turn the crankshaft counterclockwise 30° past the "0" timing mark, and then turn it clockwise to align the notch with the "0" timing mark. Turn the crankshaft slightly to eliminate the slack in the chain. HINT: Make sure there is some slack in the chain around the area where the chain tensioner is installed. While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration. TEXT IN ILLUSTRATION *1 Stopper Plate *a Push While turning the stopper plate of the tensioner counterclockwise, insert a pin of 1.27 mm diameter (0.0500 in.) into the holes in the stopper plate and tensioner to secure the stopper plate in place. Install the chain tensioner with the 2 bolts. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) Remove the pin from the No. 1 chain tensioner.
12. INSPECT VALVE TIMING Check the camshaft timing marks. NOTE: Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear. If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned. Check that each camshaft timing mark is positioned as shown in the illustration. TEXT IN ILLUSTRATION *1 Timing Mark *a Viewpoint NOTE: For Intake Camshaft: Be sure to check mark A at the point when marks B, C and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly. If the valve timing is misaligned, reinstall the timing chain. Turn the crankshaft 2 revolutions, set the No. 1 cylinder to TDC / compression and check the timing marks again.
13. INSTALL TIMING CHAIN COVER PLATE Install a new gasket and the timing chain cover plate with the 4 bolts. Torque: 9.0 N*m ( 92 kgf*cm, 80 in.*lbf)
14. POUR ENGINE OIL HINT: Before installing the cylinder head cover, pour engine oil into the locations shown in the illustration.
15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY Install 3 new gaskets as shown in the illustration. Install a new gasket to the head cover. Apply seal packing as shown in the illustration. TEXT IN ILLUSTRATION *1 Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surfaces. Install the head cover within 3 minutes of applying seal packing. Do not start the engine for at least 2 hours after installation. Install the cylinder head cover sub-assembly with the 14 bolts. for bolt A Torque: 21 N*m ( 214 kgf*cm, 15 ft.*lbf) for bolts except A Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) HINT: Make sure the removed parts are returned to the same places they were removed from.
16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH Install 3 new gaskets as shown in the illustration. Install a new gasket to the head cover. Apply seal packing as shown in the illustration. TEXT IN ILLUSTRATION *1 Seal Packing Seal packing Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent NOTE: Remove any oil from the contact surfaces. Install the head cover within 3 minutes of applying seal packing. Do not start the engine for at least 2 hours after installation. Install the cylinder head cover sub-assembly LH with the 12 bolts. for bolt A Torque: 21 N*m ( 214 kgf*cm, 15 ft.*lbf) for bolts except A Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) HINT: Make sure the removed parts are returned to the same places they were removed from.
17. INSTALL NO. 2 OIL PIPE See step 54
18. INSTALL NO. 1 OIL PIPE Make sure that there is no foreign matter on the mesh of the oil control valve filter LH. NOTE: Do not touch the mesh when installing the oil control valve filter. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side). Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil pipe check valve bolt. Tighten the oil pipe union (on the head cover side). Torque: 60 N*m ( 612 kgf*cm, 44 ft.*lbf) Tighten the oil check valve bolt (on the cylinder head side). Torque: 60 N*m ( 612 kgf*cm, 44 ft.*lbf) NOTE: If the link that connects the gasket is broken, remove the connecting link by using nippers or similar tools. Connect the connectors.
19. INSTALL SPARK PLUG See step 58
20. INSTALL IGNITION COIL ASSEMBLY . Refer to «INSTALLATION - Step 1»(/lexus/gs/iii-2007-2011/remont/ignition-system/#ignition-service-information)
21. INSTALL INJECTOR DRIVER See step 21
22. INSTALL NO. 1 ENGINE COVER See step 28
23. INSTALL WATER FILLER ASSEMBLY Install the water filler assembly with the bolt. Torque: 13 N*m ( 130 kgf*cm, 9 ft.*lbf) Connect the 2 hoses.
24. INSTALL SKID CONTROL ECU HINT: Refer to «INSTALLATION»(ref-386953-S04944915932011022400000) .
25. INSTALL FUEL PUMP ASSEMBLY Refer to «INSTALLATION»(ref-387088-S40476960552011022400000) .
26. INSTALL ECM Refer to «INSTALLATION»(ref-387086-S08610773642011022400000) .
27. INSTALL INVERTER WITH CONVERTER ASSEMBLY Refer to «INSTALLATION»(ref-387078-S06784377882011022400000) .

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1. DISCHARGE FUEL SYSTEM PRESSURE . Refer to «REMOVAL - Step 2»(ref-387088-S34306327892011022400000)
2. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM . Refer to «REPLACEMENT - Step 1»(ref-387082-S36888907422011022400000)
3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
4. REMOVE LUGGAGE COMPARTMENT FLOOR MAT
5. REMOVE BATTERY SERVICE HOLE COVER LH . Refer to «REMOVAL - Step 4»(ref-387094-S41672529212011022400000)
6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL WARNING: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
7. REMOVE SERVICE PLUG GRIP . Refer to «REMOVAL - Step 6»(ref-387094-S41672529212011022400000)
8. DRAIN ENGINE OIL . Refer to «REPLACEMENT - Step 1»(ref-387097-S24520589902011022400000)
9. DRAIN ENGINE COOLANT . Refer to «REPLACEMENT - Step 5»(ref-387077-S08483786142011022400000)
10. REMOVE COOL AIR INTAKE DUCT SEAL Remove the 7 clips and intake duct seal.
11. REMOVE ENGINE ROOM SIDE COVER RH Remove the 3 clips and side cover.
12. REMOVE ENGINE ROOM SIDE COVER LH Remove the 4 clips and side cover.
13. 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.
14. REMOVE FRONT WHEELS
15. REMOVE ENGINE UNDER COVER . Refer to «REMOVAL - Step 3»(ref-387098-S40753053842011022400000)
16. REMOVE NO. 2 ENGINE UNDER COVER Remove the 4 screws, 2 grommets, 2 spacers and under cover.
17. REMOVE REAR ENGINE UNDER COVER RH Remove the bolt and under cover.
18. REMOVE REAR ENGINE UNDER COVER LH Remove the bolt and under cover.
19. REMOVE FRONT FLOOR BRACE CENTER . Refer to «REMOVAL - Step 4»(/lexus/gs/iii-2007-2011/remont/exhaust/#exhaust-service-information)
20. REMOVE FRONT EXHAUST PIPE ASSEMBLY . Refer to «REMOVAL - Step 6»(/lexus/gs/iii-2007-2011/remont/exhaust/#exhaust-service-information)
21. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY . Refer to «REMOVAL - Step 3»(/lexus/gs/iii-2007-2011/remont/driveshaft-universal-joints/#propeller-shaft-service-information)
22. REMOVE NO. 1 AIR CLEANER INLET Remove the bolt and air cleaner inlet.
23. DISCONNECT NO. 2 VENTILATION HOSE . Refer to «REMOVAL - Step 7»(ref-387086-S18977169102011022400000)
24. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE . Refer to «REMOVAL - Step 8»(ref-387086-S18977169102011022400000)
25. REMOVE AIR CLEANER CASE Remove the 3 bolts, 2 clamps and case.
26. REMOVE OIL PUMP MOTOR CONTROLLER . Refer to «REMOVAL - Step 11»(ref-387099-S38611595782011022400000)
27. DISCONNECT NO. 2 PURGE LINE HOSE Remove the clamp and disconnect the purge line hose.
28. DISCONNECT RADIATOR HOSE INLET
29. DISCONNECT RADIATOR HOSE OUTLET
30. DISCONNECT OIL COOLER HOSE . Refer to «REMOVAL - Step 11»(ref-387077-S02772577342011022400000)
31. DISCONNECT RADIATOR RESERVE TANK HOSE
32. DISCONNECT HEATER WATER INLET HOSE A Disconnect the inlet hose.
33. DISCONNECT HEATER WATER OUTLET HOSE A Disconnect the outlet hose.
34. DISCONNECT INVERTER COOLING HOSE Disconnect the inverter cooling hose.
35. DISCONNECT NO. 8 INVERTER COOLING HOSE Disconnect the No. 8 inverter cooling hose.
36. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE . Refer to «REMOVAL - Step 7»(ref-387082-S16844897582011022400000)
37. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY . Refer to «REMOVAL - Step 8»(ref-387082-S16844897582011022400000)
38. REMOVE HYBRID VEHICLE CONTROL ECU . Refer to «REMOVAL - Step 9»(ref-387078-S23990818322011022400000)
39. REMOVE ECM . Refer to «REMOVAL - Step 7»(ref-387086-S06499058262011022400000)
40. DISCONNECT ENGINE WIRE Disconnect the clamp from the body. Remove the nut and disconnect the No. 4 engine wire. Disconnect the 2 clamps. Disconnect the 2 connectors from the compressor assembly. Remove the nut and disconnect the No. 2 wire. Disconnect the clamp from the body. Remove the bolt and disconnect the No. 3 engine wire. Remove bolt (A) to disconnect the ground wire from the bracket. Remove the 2 clamps to disconnect the wire harness from the bracket. Disconnect 2 connectors (C) and (D) from the power steering link assembly. Release the lock of connector (E) and disconnect connector (E) from the power steering link assembly. Remove bolt (B) and the power steering ground wire from the power steering link assembly. Remove the nut and ground wire. Disconnect the clamp and connector from the heater water pump. w/ Front Active Stabilizer Control Actuator: Remove the 8 bolts and fold back the front fender liner RH. Remove the bolt and disconnect the ground wire. Disconnect the wire harness clamp from the bracket. Using the procedures below, disconnect the connector from the front active stabilizer control ECU. Release the lever's lock (*1). Press the claw and move the lever in the direction of the arrow in the illustration (*2). Disconnect the connector (*3). NOTE: When disconnecting the connector, do not apply excessive force to the wire harness.
41. REMOVE HEATER WATER PUMP ASSEMBLY Disconnect the 2 hoses and remove the water pump.
42. DISCONNECT FUEL TUBE SUB-ASSEMBLY for RH Side: Disconnect the fuel tube. Refer to «PRECAUTION»(/lexus/gs/iii-2007-2011/remont/fuel-system/#fuel-inspection__precaution) . for LH Side: Disconnect the fuel tube. Refer to «PRECAUTION»(/lexus/gs/iii-2007-2011/remont/fuel-system/#fuel-inspection__precaution) .
43. DISCONNECT NO. 3 FUEL HOSE SUB-ASSEMBLY Disconnect the fuel hose from the pipe.
44. REMOVE FRONT SUSPENSION MEMBER PROTECTOR LOWER Remove the 4 bolts and protector.
45. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY . Refer to «REMOVAL - Step 7»(ref-387100-S04136206212011022400000)
46. DISCONNECT HEIGHT CONTROL SENSOR LINK Remove the nut and disconnect the height control sensor link.
47. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH . Refer to «REMOVAL - Step 9»(ref-386957-S10790861142011022400000)
48. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH . Refer to «REMOVAL - Step 9»(ref-386957-S10790861142011022400000)
49. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH . Refer to «REMOVAL - Step 9»(ref-386957-S30103804922011022400000)
50. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH . Refer to «REMOVAL - Step 9»(ref-386957-S30103804922011022400000)
51. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY . Refer to «REMOVAL - Step 19»(ref-387099-S24579391752011022400000)
52. REMOVE ENGINE AND TRANSMISSION Set an engine lifter. Remove the 4 bolts, then separate the engine rear mounting member. Remove the 12 bolts shown in the illustration. Operate the engine lifter, then slowly remove the engine from the vehicle. NOTE: Make sure the engine is clear of all wiring and hoses. Install the 2 engine hangers with the 4 bolts as shown in the illustration. PART NO.: No. 1 engine hanger 12281-31070 No. 2 engine hanger 12282-31050 Bolts 91671-10825 Torque: 33 N*m ( 336 kgf*cm, 24 ft.*lbf) Attach an engine sling device and hang the engine with a chain block.
53. REMOVE OIL DIPSTICK GUIDE Remove the dipstick. Remove the bolt and No. 2 guide. Remove the bolt and No. 1 guide. Remove the 2 O-rings from the dipstick guides.
54. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Disconnect the heated oxygen sensor connector. Remove the 6 nuts, exhaust manifold and gasket.
55. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Disconnect the heated oxygen sensor connector. Remove the 6 nuts, exhaust manifold and gasket.
56. REMOVE HYBRID VEHICLE TRANSMISSION ASSEMBLY Remove the hybrid vehicle transmission assembly. Refer to «REMOVAL»(ref-387099-S32618860372011022400000) .
57. REMOVE FLYWHEEL SUB-ASSEMBLY Using SST, hold the crankshaft. SST: 09213-70011 09213-70020 SST: 09330-00021 Remove the 9 bolts and transmission input damper cover. Remove the 8 bolts and flywheel.
58. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Remove the 2 bolts, then remove the crossmember from the engine.
59. INSTALL ENGINE STAND Install the engine onto an engine stand with the bolts. Remove the 4 bolts and 2 engine hangers.
60. REMOVE FAN & GENERATOR V BELT See step 3
61. REMOVE NO. 2 ENGINE COVER Disconnect the harness clamp. Remove the 3 clips and cover.
62. REMOVE NO. 1 ENGINE COVER Remove the 3 clips and cover.
63. REMOVE ELECTRIC INVERTER COMPRESSOR . Refer to «REMOVAL - Step 9»(ref-387082-S16844897582011022400000)
64. REMOVE ENGINE MOUNTING BRACKET LH Disconnect the 2 clamps. Remove the 4 bolts and bracket.
65. REMOVE ENGINE MOUNTING BRACKET RH Remove the 4 bolts and bracket.
66. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY Remove the 5 bolts, then remove the tensioner.
67. REMOVE WATER PUMP PULLEY . Refer to «REMOVAL - Step 18»(ref-387077-S09794281592011022400000)
68. REMOVE ENGINE WIRE Remove the engine wire from the engine.
69. REMOVE INJECTOR DRIVER Remove the bolt, 2 nuts and injector driver.
70. REMOVE INTAKE AIR SURGE TANK SUB-ASSEMBLY . Refer to «REMOVAL - Step 20»(ref-387088-S34306327892011022400000)
71. REMOVE NO. 2 INTAKE AIR SURGE TANK BRACKET Remove the bolt and bracket.
72. REMOVE NO. 3 WATER BY-PASS PIPE Remove the bolt. Disconnect the 2 hoses and remove the pipe.
73. REMOVE INTAKE MANIFOLD . Refer to «REMOVAL - Step 21»(ref-387088-S05735139422011022400000)
74. REMOVE FUEL TUBE SUB-ASSEMBLY Remove the 2 bolts and tube.
75. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY . Refer to «REMOVAL - Step 18»(ref-387088-S06544965352011022400000)
76. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY Disconnect the 2 hoses. Remove the 2 bolts and pipe.
77. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY . Refer to «REMOVAL - Step 27»(ref-387088-S05735139422011022400000)
78. REMOVE HIGH PRESSURE SIDE FUEL PUMP . Refer to «REMOVAL - Step 25»(ref-387088-S23985215352011022400000)
79. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY . Refer to «REMOVAL - Step 28»(ref-387088-S05735139422011022400000)
80. REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to «REMOVAL - Step 29»(ref-387088-S05735139422011022400000)
81. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to «REMOVAL - Step 30»(ref-387088-S05735139422011022400000)
82. REMOVE FUEL INJECTOR ASSEMBLY for Port: Remove the injector assembly. Refer to «REMOVAL - Step 22»(ref-387088-S34306327892011022400000) . for Direct: Remove the injector assembly. Refer to «REMOVAL - Step 31»(ref-387088-S05735139422011022400000) .
83. REMOVE KNOCK SENSOR . Refer to «REMOVAL - Step 32»(ref-387086-S38986613362011022400000)
84. REMOVE RADIO SETTING CONDENSER Remove the 2 bolts and 2 condensers.
85. REMOVE BANK COVER BRACKET Remove the bolt and bracket.
86. REMOVE IGNITION COIL ASSEMBLY Remove the 6 bolts and 6 ignition coils.
87. REMOVE ENGINE OIL LEVEL SENSOR Remove the 4 bolts, then remove the sensor and gasket.
88. REMOVE OIL PRESSURE SWITCH ASSEMBLY Using a 24 mm deep socket wrench, remove the switch.
89. REMOVE ENGINE COOLANT TEMPERATURE SENSOR Using a 19 mm deep socket wrench, remove the sensor and gasket.

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1. INSPECT INTAKE MANIFOLD Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head and intake air surge tank. Standard maximum warpage Item Specified Condition Intake manifold side 0.1 mm (0.003 in.) Cylinder head side 0.1 mm (0.003 in.) If the warpage is greater than the maximum, replace the intake manifold.
2. INSPECT INTAKE AIR SURGE TANK ASSEMBLY Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head. Standard maximum warpage 2.5 mm (0.098 in.) If the warpage is greater than the maximum, replace the surge tank.
3. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head. Maximum warpage 0.7 mm (0.028 in.) If the warpage is greater than the maximum, replace the exhaust manifold.
4. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of the cylinder head. Maximum warpage 0.7 mm (0.028 in.) If the warpage is greater than the maximum, replace the exhaust manifold.

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1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Install a new gasket to the sensor. Using a 19 mm deep socket wrench, remove the temperature sensor. Torque: 20 N*m ( 204 kgf*cm, 15 ft.*lbf)
2. INSTALL OIL PRESSURE SWITCH ASSEMBLY 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: 15 N*m ( 153 kgf*cm, 11 ft.*lbf) NOTE: Do not start the engine within 1 hour after installation.
3. INSTALL ENGINE OIL LEVEL SENSOR Install the engine oil level sensor and new gasket with the 4 bolts. Torque: 7.0 N*m ( 71 kgf*cm, 62 in.*lbf)
4. INSTALL IGNITION COIL ASSEMBLY Install the 6 ignition coils with the 6 bolts. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf)
5. INSTALL BANK COVER BRACKET Install the bracket with the bolt. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf)
6. INSTALL RADIO SETTING CONDENSER Install the 2 condensers with the 2 bolts. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf)
7. INSTALL KNOCK SENSOR . Refer to «INSTALLATION - Step 1»(ref-387086-S41526753622011022400000)
8. INSTALL FUEL INJECTOR ASSEMBLY for Port: Install the injector assembly. Refer to «INSTALLATION - Step 1»(ref-387088-S15542054702011022400000) . for Direct: Install the injector assembly. Refer to «INSTALLATION - Step 2»(ref-387088-S14039927412011022400000) .
9. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 3»(ref-387088-S14039927412011022400000)
10. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 4»(ref-387088-S14039927412011022400000)
11. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 5»(ref-387088-S14039927412011022400000)
12. INSTALL HIGH PRESSURE SIDE FUEL PUMP . Refer to «INSTALLATION - Step 1»(ref-387088-S01350685342011022400000)
13. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 6»(ref-387088-S14039927412011022400000)
14. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY Install the pipe with the 2 bolts. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) Connect the 2 hoses.
15. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-387088-S36644433202011022400000)
16. INSTALL FUEL TUBE SUB-ASSEMBLY Install the tube with the 2 bolts. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf)
17. INSTALL INTAKE MANIFOLD . Refer to «INSTALLATION - Step 12»(ref-387088-S14039927412011022400000)
18. INSTALL NO. 3 WATER BY-PASS PIPE Connect the 2 hoses. Install the pipe with the bolt. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf)
19. INSTALL NO. 2 INTAKE AIR SURGE TANK BRACKET NOTE: Make sure there is no oil on the bolts. If there is oil on the bolts, clean them before installing them. Install the bracket with the bolt. Torque: 21 N*m ( 214 kgf*cm, 15 ft.*lbf)
20. INSTALL INTAKE AIR SURGE TANK SUB-ASSEMBLY . Refer to «INSTALLATION - Step 3»(ref-387088-S15542054702011022400000)
21. INSTALL INJECTOR DRIVER Install the injector driver with the bolt and 2 nuts. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf)
22. INSTALL ENGINE WIRE Install the engine wire to the engine assembly.
23. INSTALL WATER PUMP PULLEY . Refer to «INSTALLATION - Step 1»(ref-387077-S41287684902011022400000)
24. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Temporarily install the V-ribbed belt tensioner with the 5 bolts. Each bolt length is as follows Bolt Length A 70 mm (2.76 in.) B 33 mm (1.30 in.) Install the V-ribbed belt tensioner by tightening 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)
25. INSTALL ENGINE MOUNTING BRACKET LH Install the bracket with the 4 bolts. Torque: 43 N*m ( 438 kgf*cm, 32 ft.*lbf) Connect the 2 clamps.
26. INSTALL ENGINE MOUNTING BRACKET RH Install the bracket with the 4 bolts. Torque: 43 N*m ( 438 kgf*cm, 32 ft.*lbf)
27. INSTALL ELECTRIC INVERTER COMPRESSOR . Refer to «INSTALLATION - Step 2»(ref-387082-S37061646732011022400000)
28. INSTALL NO. 1 ENGINE COVER Install the cover with the 3 clamps.
29. INSTALL NO. 2 ENGINE COVER Install the cover with the 3 clamps. Connect the clamp.
30. INSTALL FAN & GENERATOR V BELT See step 1
31. REMOVE ENGINE STAND Install the 2 engine hangers with the 4 bolts as shown in the illustration. PART NO.: No. 1 engine hanger 12281-31070 No. 2 engine hanger 12282-31050 Bolt 91671-10825 Torque: 33 N*m ( 336 kgf*cm, 24 ft.*lbf) Attach an engine sling device and hang the engine with a chain block. Remove the engine assembly from the engine stand.
32. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Install the front suspension crossmember sub-assembly with the 2 bolts. Torque: 35 N*m ( 357 kgf*cm, 26 ft.*lbf)
33. INSTALL FLYWHEEL SUB-ASSEMBLY Using SST, hold the crankshaft. SST: 09213-70011 09213-70020 SST: 09330-00021 Apply adhesive to 2 or 3 threads of the mounting bolts end. Adhesive Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent Install and tighten the 8 mounting bolts uniformly in several steps. Torque: 83 N*m ( 850 kgf*cm, 61 ft.*lbf) NOTE: Do not start the engine for at least 1 hour after installing. Install the transmission input damper cover with the 9 bolts. Torque: 49 N*m ( 504 kgf*cm, 36 ft.*lbf)
34. INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY Install the hybrid vehicle transmission assembly. Refer to «INSTALLATION»(ref-387099-S23502162142011022400000) .
35. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Install a new gasket as shown in the illustration. Install the exhaust manifold to the cylinder head with the 6 nuts in the order shown in the illustration. Torque: 21 N*m ( 214 kgf*cm, 15 ft.*lbf) NOTE: Do not damage the stud bolt when installing the exhaust manifold.
36. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Install a new gasket as shown in the illustration. Install the exhaust manifold to the cylinder head with the 6 nuts in the order shown in the illustration. Torque: 21 N*m ( 214 kgf*cm, 15 ft.*lbf) NOTE: Do not damage the stud bolt when installing the exhaust manifold.
37. INSTALL OIL DIPSTICK GUIDE Install a new O-ring to the guide. Apply a light coat of engine oil to the O-ring. Push in the No. 1 guide end into the guide hole. Install the No. 1 guide with the bolt. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) Connect the harness clamp. Install a new O-ring to the guide. Apply a light coat of engine oil to the O-ring. Push in the No. 2 guide end into the No. 1 guide hole. Install the No. 2 guide with the bolt. Torque: 21 N*m ( 214 kgf*cm, 15 ft.*lbf) Install the dipstick.
38. INSTALL ENGINE AND TRANSMISSION Remove the 4 bolts and 2 engine hangers. Set an engine lifter. Operate the engine lifter, then install the engine to the vehicle. Install the engine and transmission with crossmember sub-assembly with the 12 bolts. Torque: 167 N*m ( 1,700 kgf*cm, 123 ft.*lbf) for bolt A Torque: 204 N*m ( 2,080 kgf*cm, 150 ft.*lbf) for bolt B Torque: 50 N*m ( 510 kgf*cm, 37 ft.*lbf) for bolt C Torque: 49 N*m ( 500 kgf*cm, 36 ft.*lbf) for bolt D Install the engine rear mounting member with the 4 bolts. Torque: 26 N*m ( 265 kgf*cm, 19 ft.*lbf)
39. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY . Refer to «INSTALLATION - Step 2»(ref-387099-S24154981752011022400000)
40. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH . Refer to «INSTALLATION - Step 1»(ref-386957-S19024501932011022400000)
41. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH . Refer to «INSTALLATION - Step 1»(ref-386957-S19024501932011022400000)
42. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH . Refer to «INSTALLATION - Step 8»(ref-386957-S03284772002011022400000)
43. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH . Refer to «INSTALLATION - Step 8»(ref-386957-S03284772002011022400000)
44. CONNECT HEIGHT CONTROL SENSOR LINK Connect the height control sensor link and install it with the nut. Torque: 5.4 N*m ( 55 kgf*cm, 48 in.*lbf)
45. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER Install the protector with the 4 bolts. Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf)
46. CONNECT NO. 3 FUEL HOSE SUB-ASSEMBLY Connect the fuel hose to the pipe.
47. CONNECT FUEL TUBE SUB-ASSEMBLY for RH Side: Connect the fuel tube. Refer to «PRECAUTION»(/lexus/gs/iii-2007-2011/remont/fuel-system/#fuel-inspection__precaution) . for LH Side: Connect the fuel tube. Refer to «PRECAUTION»(/lexus/gs/iii-2007-2011/remont/fuel-system/#fuel-inspection__precaution) .
48. INSTALL HEATER WATER PUMP ASSEMBLY Connect the 2 hoses and install the water pump.
49. CONNECT ENGINE WIRE w/ Front Active Stabilizer Control Actuator: Using the procedures below, connect the connector to the front active stabilizer control ECU. Connect the connector to the front active stabilizer control (*1). Rotate the lever in the direction of the arrow until a "click" sound is heard (*2). Lock the lever's lock (*3). Install the wire clamp to the bracket. Install the ground wire to the front active stabilizer control ECU with the bolt. Torque: 10 N*m ( 102 kgf*cm, 7 ft.*lbf) Install the front fender liner RH with the 8 bolts. Connect the clamp and connector to the heater water pump. Install the ground wire with the nut. Torque: 5.4 N*m ( 55 kgf*cm, 48 in.*lbf) Install the power steering ground wire to the power steering link assembly with bolt (B). Torque: 5.0 N*m ( 51 kgf*cm, 44 in.*lbf) Connect wire harness connector (E) to the power steering link assembly and securely lock the connector. Connect 2 wire harness connectors (C) and (D) to the power steering link assembly. Install the 2 wire harness clamps to the power steering link assembly. Connect the ground wire to the bracket with bolt (A). Torque: 8.0 N*m ( 82 kgf*cm, 71 in.*lbf) Install the No. 3 engine wire with the bolt. Torque: 8.5 N*m ( 87 kgf*cm, 75 in.*lbf) Connect the clamp to the body. Install the No. 2 wire with the nut. Torque: 13 N*m ( 133 kgf*cm, 10 ft.*lbf) Connect the 2 connectors to the compressor assembly. Connect the 2 clamps. Install the No. 4 engine wire with the nut. Torque: 12 N*m ( 122 kgf*cm, 9 ft.*lbf) Connect the clamp to the body.
50. INSTALL ECM . Refer to «INSTALLATION - Step 1»(ref-387086-S41028831792011022400000)
51. INSTALL HYBRID VEHICLE CONTROL ECU . Refer to «INSTALLATION - Step 1»(ref-387078-S30316035402011022400000)
52. CONNECT DISCHARGE HOSE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 3»(ref-387082-S37061646732011022400000)
53. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE . Refer to «INSTALLATION - Step 4»(ref-387082-S37061646732011022400000)
54. CONNECT NO. 8 INVERTER COOLING HOSE Connect the No. 8 inverter cooling hose.
55. CONNECT INVERTER COOLING HOSE Connect the inverter cooling hose.
56. CONNECT HEATER WATER OUTLET HOSE A Connect the outlet hose.
57. CONNECT HEATER WATER INLET HOSE A Connect the inlet hose.
58. CONNECT RADIATOR RESERVE TANK HOSE
59. CONNECT OIL COOLER HOSE . Refer to «INSTALLATION - Step 4»(ref-387077-S10277453512011022400000)
60. CONNECT RADIATOR HOSE INLET
61. CONNECT RADIATOR HOSE OUTLET
62. CONNECT NO. 2 PURGE LINE HOSE Connect the purge line hose.
63. INSTALL OIL PUMP MOTOR CONTROLLER . Refer to «INSTALLATION - Step 1»(ref-387099-S02022377112011022400000)
64. INSTALL AIR CLEANER CASE Install the case with the 3 bolts. Torque: 5.0 N*m ( 51 kgf*cm, 44 in.*lbf) Connect the 2 clamps.
65. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE . Refer to «INSTALLATION - Step 2»(ref-387086-S27474421112011022400000)
66. INSTALL NO. 2 VENTILATION HOSE . Refer to «INSTALLATION - Step 3»(ref-387086-S27474421112011022400000)
67. INSTALL NO. 1 AIR CLEANER INLET Install the air cleaner inlet with the bolt. Torque: 5.0 N*m ( 51 kgf*cm, 44 in.*lbf)
68. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY . Refer to «INSTALLATION - Step 1»(/lexus/gs/iii-2007-2011/remont/driveshaft-universal-joints/#propeller-shaft-service-information)
69. INSTALL FRONT EXHAUST PIPE ASSEMBLY . Refer to «INSTALLATION - Step 4»(/lexus/gs/iii-2007-2011/remont/exhaust/#exhaust-service-information)
70. INSTALL FRONT FLOOR BRACE CENTER . Refer to «INSTALLATION - Step 6»(/lexus/gs/iii-2007-2011/remont/exhaust/#exhaust-service-information)
71. ADD ENGINE OIL . Refer to «REPLACEMENT - Step 5»(ref-387097-S24520589902011022400000)
72. ADD ENGINE COOLANT . Refer to «REPLACEMENT - Step 6»(ref-387077-S08483786142011022400000)
73. CHARGE REFRIGERANT . Refer to «REPLACEMENT - Step 2»(ref-387082-S36888907422011022400000)
74. INSTALL SERVICE PLUG GRIP . Refer to «INSTALLATION - Step 33»(ref-387094-S08557413472011022400000)
75. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
76. INSTALL BATTERY SERVICE HOLE COVER LH . Refer to «INSTALLATION - Step 35»(ref-387094-S08557413472011022400000)
77. INSTALL LUGGAGE COMPARTMENT FLOOR MAT
78. PERFORM INITIALIZATION Perform initialization. Refer to «INITIALIZATION»(ref-386951-S21829001392011022400000) . NOTE: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.
79. INSPECT FOR ENGINE OIL LEAK . Refer to «ON-VEHICLE INSPECTION - Step 8»(/lexus/gs/iii-2007-2011/remont/lubrication-system/#lubrication-inspection)
80. INSPECT FOR ENGINE COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(/lexus/gs/iii-2007-2011/remont/cooling-system-mechanical/#cooling-inspection)
81. INSPECT FOR FUEL LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(/lexus/gs/iii-2007-2011/remont/fuel-system/#fuel-inspection)
82. INSPECT FOR REFRIGERANT LEAK . Refer to «REPLACEMENT - Step 4»(ref-387082-S36888907422011022400000)
83. INSPECT FOR EXHAUST GAS LEAK
84. INSTALL REAR ENGINE UNDER COVER LH Install the under cover with the bolt.
85. INSTALL REAR ENGINE UNDER COVER RH Install the under cover with the bolt.
86. INSTALL FRONT WHEELS
87. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
88. CHECK SHIFT LEVER POSITION
89. CHECK AND ADJUST FRONT WHEEL ALIGNMENT Check and adjust the front wheel alignment. Refer to «ADJUSTMENT»(ref-386957-S37344048512011022400000) .
90. CHECK IGNITION TIMING See step 2
91. CHECK IDLE SPEED See step 3
92. CHECK CO / HC See step 5
93. CHECK ENGINE OIL LEVEL . Refer to «ON-VEHICLE INSPECTION - Step 1»(/lexus/gs/iii-2007-2011/remont/lubrication-system/#lubrication-inspection)
94. CHECK ENGINE COOLANT LEVEL . Refer to «ON-VEHICLE INSPECTION - Step 2»(/lexus/gs/iii-2007-2011/remont/cooling-system-mechanical/#cooling-inspection)
95. INSTALL NO. 2 ENGINE UNDER COVER Install the under cover with the 4 screws, 2 grommets and 2 spacers.
96. INSTALL ENGINE UNDER COVER . Refer to «INSTALLATION - Step 7»(ref-387098-S17527170762011022400000)
97. INSTALL V-BANK COVER SUB-ASSEMBLY Attach the 3 clips to install the engine cover. NOTE: Be sure to engage the clips securely. Do not apply excessive force or do not hit the cover to engage the clips. This may cause the cover to break.
98. INSTALL ENGINE ROOM SIDE COVER RH Install the side cover with the 3 clips.
99. INSTALL ENGINE ROOM SIDE COVER LH Install the side cover with the 4 clips.
100. INSTALL COOL AIR INTAKE DUCT SEAL Install the intake duct seal with the 7 clips.

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

See also:
• REMOVAL - Step 9
• REMOVAL - Step 4
• REMOVAL - Step 3
• PRECAUTION
• ON-VEHICLE INSPECTION - Step 8
• ON-VEHICLE INSPECTION - Step 1
• ON-VEHICLE INSPECTION - Step 1