Engine Mechanical: Removal & Installation Lexus IS I

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.

Refer to these figures throughout procedure. (Scheme 15)- (Scheme 25).

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159232-S05051900452003111900000) . Remove battery. Drain cooling system and engine oil. Remove hood. Remove air cleaner intake. Disconnect brake booster and vacuum hoses. Disconnect upper and lower radiator hoses from engine. Disconnect air cleaner, MAF meter and intake air connector pipe assembly. Disconnect control cables at throttle body. NOTE: Place reference mark on fan clutch and water pump for reassembly reference.
2. Remove front suspension member brace from undercarriage. Disconnect necessary electrical connections and brackets, coolant hoses, fuel lines and vacuum hoses. Remove drive belt, cooling fan, fluid coupling assembly and water pump pulley. Remove radiator assembly.
3. Disconnect Evaporative Emission Control (EVAP) hose from Vacuum Switching Valve (VSV) for EVAP. Disconnect necessary connectors, wires and hoses.
4. Remove ECM hood and ECM cover. Disconnect 3 ECM connectors and 4 wire harness connectors. Disconnect 2 junction connectors. Disconnect grommet and engine wire from ECM box.
5. Remove 2 bolts from rear bracket of power steering. Remove 3 bolts from front power steering bracket. DO NOT disconnect hoses. Disconnect Progressive Power Steering (PPS) solenoid valve connector. Disconnect A/C electrical connector. Remove 2 bolts from A/C compressor to engine. Position A/C compressor and power steering pump aside and secure for engine removal access.
6. Raise and support vehicle. Remove lower engine covers. Ensure steering wheel is at straight-ahead position. Place reference marks on sliding yoke and intermediate steering shaft. Remove bolt and disconnect sliding yoke from intermediate steering shaft. Remove nut, and disconnect starter wire. Disconnect power steering feed hose. Remove exhaust manifold. Remove exhaust pipe heat insulator.
7. Reference mark intermediate drive shaft companion flanges for reassembly reference. Remove center support bearing bolts. Note location of adjusting washers (if equipped) between center bearing and frame.
8. Remove intermediate drive shaft companion flange bolts. Remove intermediate drive shaft and center bearing. On A/T models, disconnect transmission control rod. On M/T models, disconnect clutch release cylinder from transmission. Remove front and center exhaust pipes. Remove 2 nuts from stabilizer bar links. Remove 4 bolts and 2 stabilizer bar brackets with bushings.
9. Remove nut and bolt from lower shock absorber. Disconnect shock absorber from lower suspension arm. Remove nut and disconnect height level sensor from lower suspension arm. Remove 2 bolts and disconnect lower arm from steering knuckle.
10. Support engine with hoist. Remove 4 bolts and disconnect rear engine mounting. Remove 4 bolts and disconnect suspension member from vehicle body. Lift engine from vehicle. Ensure engine is clear of all wiring, hoses and cables. On A/T vehicles, remove dipstick and oil guide.
11. Disconnect oxygen sensor. Remove 8 nuts and disconnect exhaust manifold from engine. Remove oil cooler pipes. Remove drain plug and 6 bolts from torque converter. Remove 4 No. 1 oil pan-to-transmission bolts. Remove starter. Disconnect engine wires from transmission. Separate engine and transmission. Remove drive plate.

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Installation

1. To install, reverse removal procedure. Install NEW nuts when installing exhaust pipe components. Ensure reference marks on drive shaft companion flanges are aligned. CAUTION: Install intermediate drive shaft center bearing so bracket on center bearing is parallel to drive shaft.
2. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-159232-S31757476362003111900000) . Adjust fluid levels, control cables and shift linkage (if necessary).

Refer to these figures throughout procedure. (Scheme 15)- (Scheme 25).

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159232-S05051900452003111900000). 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 Acoustic Control Induction System (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. 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. see scheme 29 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. see scheme 30 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.

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. see scheme 30 See «TORQUE SPECIFICATIONS»(ref-159232-S31757476362003111900000).
2. Install camshafts. See «CAMSHAFT»(ref-159232-S01079190232003111900000). Check and adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(ref-159232-S06833234782003111900000) 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-159232-S31757476362003111900000).
4. Before installing gaskets and valve covers, apply sealant at indicated areas on front of cylinder head. see scheme 4 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-159232-S31757476362003111900000).

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.

Refer to these figures throughout procedure. (Scheme 15)- (Scheme 25).

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.

Refer to these figures throughout procedure. (Scheme 15)- (Scheme 25).

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159232-S05051900452003111900000). 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 Acoustic Control Induction System (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. 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. 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. see scheme 29 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).

Refer to these figures throughout procedure. (Scheme 15)- (Scheme 25).

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-159232-S31757476362003111900000) . 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". see scheme 34 Install nuts holding water by-pass pipe to water pump. Tighten all water pump bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159232-S31757476362003111900000).
3. To complete installation, reverse removal procedure. Fill engine with coolant. Check for leaks.

Refer to these figures throughout procedure. (Scheme 15)- (Scheme 25).

1. Remove engine. See «ENGINE»(ref-159232-S14115220062003111900000). 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 26)
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 26) 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 26)or (Scheme 27). Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS.

Scheme 26

Scheme 27

Removal & Disassembly

Refer to these figures throughout procedure. (Scheme 15)- (Scheme 25).

1. Remove engine. See «ENGINE»(ref-159232-S14115220062003111900000) 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 under REMOVAL & INSTALLATION.
2. Remove oil pan. See «OIL PAN»(ref-159232-S37991944912003111900000) 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 28) 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-159232-S31757476362003111900000) .
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-159232-S31757476362003111900000) .
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 28