4.3L V8: Removal & Installation Lexus LS III

REMOVAL & INSTALLATION

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

Removal (GS430)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-131978-S25275201342002010500000) . Remove hood. Remove battery cover and battery. Raise and support vehicle. Remove engine under covers. Remove 6 bolts and remove suspension brace. Drain cooling system and engine oil. Lower vehicle.
2. Remove engine "V" bank and side covers. Remove intake air duct and air cleaner assembly. Remove radiator and cooling fans assembly. Remove generator drive belt. Disconnect all necessary electrical connections, body ground straps, control cables, coolant hoses, vacuum hoses and fuel lines from engine. Disconnect power steering hoses from power steering pump.
3. Remove ECM cover and ECM hood at left front fender. Disconnect 3 electrical connectors, 4 wire harness connectors and 2 junction connectors from ECM. Disconnect grommet and engine wire from ECM box.
4. Raise and support vehicle. Remove 2 heated oxygen sensors. Remove front and center exhaust pipes. Remove both three-way catalytic converters (TWC) and gaskets. Remove center front floor brace. Remove heat insulators. Disconnect ATF cooler lines from transmission. Remove driveshaft. Lower vehicle.
5. Disconnect A/C compressor harness connector. Disconnect wire clamp from wire bracket on A/C compressor. Remove bolt, nut and A/C compressor stay. Remove bolt, and remove wire bracket from A/C compressor. Remove A/C compressor from engine and suspend aside. Disconnect power steering oil pressure switch connector. Remove 2 bolts and nut and remove power steering pump from engine. Remove 2 clips and remove transmission control rod.
6. Place steering wheel in straight-ahead position. Remove bolt holding sliding yoke to intermediate shaft. Remove bolt and disconnect 2 power steering oil tubes from front of vehicle frame. Remove 4 bolts, and disconnect power steering gear from front of vehicle frame. Suspend power steering gear securely. Disconnect sliding yoke from intermediate steering shaft.
7. Remove "V" bank cover bracket from engine hanger. Attach chain hoist to engine hangers. Remove nuts holding front engine mounts to front suspension crossmember. Remove 4 bolts, 4 nuts and rear engine mounting member. Lift engine and transmission assembly out of vehicle slowly and carefully, ensuring engine is clear of all wiring, hoses and cables. Remove 10 transmission-to-engine bolts. Remove transmission and torque converter from engine as an assembly. Remove bolts, front spacer, drive plate and rear spacer.

Installation

1. Attach chain hoist to engine hangers. Slowly lower engine and transmission assembly into engine compartment. Insert stud bolts of front engine mounting brackets into bolt holes of front suspension crossmember. Ensure engine is level.
2. Install rear engine mounting member with the 4 bolts and 4 nuts. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000) . Install 4 nuts holding engine mounting brackets to front suspension crossmember. Remove chain hoist from engine. Install "V" bank cover bracket to engine hanger.
3. Connect sliding yoke to intermediate shaft. Install bolt holding sliding yoke to intermediate shaft, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000) . Install power steering gear with 4 bolts. Install power steering tube retainer. Install front suspension member brace with 6 bolts. Install transmission control rod with 2 clips. Install driveshaft.
4. Install ATF cooler lines to transmission. Install heat insulators for front side of front exhaust pipe. Install front floor brace. Install remaining heat insulators. Install both TWC's using NEW gaskets and nuts, and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000) . Install oxygen sensors. Ensure sensor wire is not twisted after installation. Install center and front exhaust pipes.
5. Install power steering pump. Connect power steering oil pressure switch harness connector. Install A/C compressor, compressor stay and wire bracket. Connect A/C compressor harness connector. Install wire retaining clamp. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000) .
6. Install engine wire grommet to ECM box. Connect 3 ECM connectors, 4 wire harness connectors and 2 junction connectors. Install ECM hood and cover. Connect all necessary electrical connectors, brackets, control cables, coolant hoses, vacuum hoses and fuel lines.
7. Install generator drive belt. Install radiator assembly. Install intake air duct. Install air cleaner assembly. Fill crankcase with engine oil. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-131978-S36299518652002010500000) .
8. Start engine and check for leaks. Install engine "V" bank and side covers. Install engine undercovers. Install hood. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000) .

Removal (LS430)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-131978-S25275201342002010500000) . Remove hood. Remove engine "V" bank and side covers. Remove battery cover and battery. Remove air cleaner assembly and intake air duct. Raise and support vehicle. Remove engine under covers. Disconnect ATF cooler lines from radiator. Drain cooling system and engine oil. Lower vehicle.
2. Remove drive belt. Disconnect upper and lower radiator hoses from engine. Disconnect all necessary electrical connectors, body ground straps, coolant hoses, vacuum hoses, control cables and fuel lines from engine. Disconnect cooling fan harness connectors. Remove radiator assembly.
3. Disconnect power steering hoses from pump. Remove power steering pump and oil reservoir from vehicle. Remove A/C compressor from engine with hoses attached, and suspend aside. Remove ECM cover. Disconnect ECM harness connectors.
4. Raise and support vehicle. Disconnect harness connectors from heated oxygen sensors. Remove front and center exhaust pipes and tail pipes. Remove both three-way catalytic converters (TWC) from exhaust manifolds.
5. Remove exhaust pipe heat insulators. Remove center floor crossmember brace. Paint reference mark on drive shaft flanges at transmission and rear differential flange for reassembly reference.
6. Remove driveshaft center bearing bolts and adjusting washers. Adjusting washers are located between driveshaft center bearing and frame. Remove driveshaft flange bolts. Remove driveshaft.
7. Disconnect sliding yoke from intermediate steering shaft. Disconnect power steering hoses from steering gear. Remove front stabilizer bar. Disconnect shock absorbers from lower control arms.
8. Disconnect height level sensor linkage from lower control arms. Remove 2 bolts and disconnect lower control arm from steering knuckle.
9. Attach chain hoist to engine hangers and support engine. Remove 4 bolts and disconnect rear mounting crossmember from body. Remove 4 bolts and disconnect rear mounting crossmember from body.
10. Disconnect shift control rod from transmission shift lever. Remove 4 bolts and disconnect front suspension member from body. Lower engine and transmission as an assembly from vehicle.
11. Disconnect engine wire from transmission. Remove engine oil dipstick and guide tube. Remove 2 bolts and remove flywheel access cover. Turn crankshaft pulley bolt to gain access to each bolt. Remove 6 torque converter-to-flywheel bolts.
12. Remove 10 transmission-to-engine bolts. Remove transmission and torque converter from engine as an assembly. Remove bolts, front spacer, drive plate and rear spacer.

1. Apply Three Bond 1234 to threads of drive plate bolts. Install drive plate with front and rear spacers on crankshaft and tighten bolts to specification in 2 steps. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000) . Install transmission to engine. Apply Three Bond 1234 to threads of torque converter bolts and install the Black colored bolt first. Install flywheel access cover.
2. Install front suspension crossmember to engine. Using a chain hoist, lift engine and transmission assembly into vehicle. Connect front suspension crossmember to body. Install rear mounting crossmember to body. Remove chain hoist from engine.
3. Connect lower control arm to steering knuckle. Connect height level sensor linkage lower control arms. Connect shock absorbers to lower control arms. Install front stabilizer bar. Install sliding yoke to intermediate steering shaft. Install power steering hoses to steering gear.
4. Install driveshaft. Apply grease to center flexible bushing in ends of driveshaft before installing. Ensure driveshaft flange reference marks align. Using NEW gaskets and retaining nuts, install TWC's on exhaust manifolds. Install front and center exhaust pipes and tail pipes.
5. To complete installation, reverse removal procedure. Adjust control cables. Fill crankcase with engine oil. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-131978-S36299518652002010500000) .

Scheme 14

Scheme 15

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-131978-S25275201342002010500000). Disconnect negative battery cable. Drain cooling system. Remove engine "V" bank and side covers. Remove air cleaner assembly and intake air duct. Disconnect EVAP hose from charcoal canister. Remove radiator assembly. Remove 4 "V" bank cover mounting brackets.
2. Remove throttle body. Disconnect all necessary fuel lines, vacuum hoses and electrical connectors from intake manifold and cylinder heads. Remove bolts and disconnect wire harness retaining clamps from upper intake manifold, and LH camshaft bearing cap. Remove 2 bolts and disconnect wire harness retainer from RH cylinder head, and rear water bypass manifold.
3. Disconnect 8 injector connectors. Remove 6 bolts and 4 nuts, and remove intake manifold assembly. Disconnect timing belt from camshaft sprockets. «TIMING BELT»(ref-131978-S15835946542002010500000). Remove camshaft sprockets. Remove camshaft position sensor. Remove rear timing belt plates from both cylinder heads.
4. Remove power steering pump from engine and suspend aside. Raise and support vehicle. Disconnect front exhaust pipe from three-way catalytic converters (TWC) on exhaust manifolds. Remove TWC's from exhaust manifolds. Lower vehicle. Remove water bypass pipe. Disconnect water temperature sender. Remove 4 bolts and remove water bypass manifold.
5. Remove ignition coils. Remove Variable Valve Timing (VVT) sensors. Remove engine hangers. Remove engine and transmission oil dipsticks and guide tubes. Remove valve covers. Remove camshaft timing oil control valve from both front camshaft bearing caps.
6. To avoid valve/piston interference, ensure timing mark on crankshaft pulley is aligned with center of crankshaft pulley bolt and center of No. 2 timing belt idler pulley bolt. (Scheme 14) Remove camshafts. See «CAMSHAFT»(ref-131978-S29833318072002010500000).
7. Disconnect oxygen sensor harness connectors. Disconnect body ground leads from rear of each cylinder head. Remove oxygen sensor wire harness bracket from LH cylinder head. Remove wire harness bracket from RH cylinder head.
8. Loosen cylinder head bolts evenly in several steps, in sequence. (Scheme 15) Remove cylinder head bolts, washers, cylinder head and cylinder head gasket. CAUTION: To prevent cylinder head warpage or cracking, loosen cylinder head bolts evenly, in proper sequence. (Scheme 15) DO NOT allow cylinder head bolt washers to drop into engine through either end of cylinder head. 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.
9. Remove heat insulators. Remove exhaust manifolds and gaskets from cylinder head. Using a valve spring compressor, remove keepers, spring retainers, springs and valves. Using needle nose pliers, remove valve stem oil seals.

Removal & Installation (Oil Pump Installed)

1. Remove timing belt and crankshaft sprocket. See «TIMING BELT»(ref-131978-S15835946542002010500000) . Using a knife, cut seal lip from crankshaft front seal. Carefully pry crankshaft front seal from oil pump body. DO NOT damage sealing surfaces.
2. To install, apply grease to sealing lip of crankshaft front seal. Using a hammer and Seal Installer (SST 09316-60011), install NEW crankshaft front oil seal until seal surface is even with oil pump body. To install remaining components, reverse removal procedure.

Removal & Installation (Oil Pump Removed)

Using a screwdriver, pry crankshaft front seal from oil pump body. To install, use a hammer and Seal Installer (SST 09316-60011). Install NEW crankshaft front oil seal until seal surface is even with oil pump body. Apply grease to sealing lip of crankshaft front seal.

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

1. Remove engine undercover. Drain engine coolant. Remove engine "V" bank and side covers. Remove air cleaner assembly and intake air duct. Remove drive belt. Remove radiator and cooling fans assembly. Disconnect water by-pass hoses from by-pass pipe.
2. Remove wire harness from retainers on timing belt covers. Disconnect camshaft position sensor harness connector. Remove LH No. 3 timing belt cover and gasket. (Scheme 16) Remove RH No. 3 timing belt cover and gasket.
3. Remove No. 2 timing belt cover. Remove A/C compressor from engine, with hoses attached, and suspend aside. Remove No. 1 drive belt idler pulley. (Scheme 16)
4. If reusing timing belt, ensure the 3 installation marks exist on timing belt before removal. (Scheme 18) If installation marks do not exist, place installation marks on timing belt and sprockets as shown. Rotate crankshaft until pulley groove aligns with "0" mark on No. 1 timing belt cover. This position is about 50 degrees ATDC. DO NOT turn crankshaft, and loosen crankshaft pulley bolt. CAUTION: DO NOT rotate camshafts or crankshafts after timing belt is removed. Piston/valve contact could occur and damage engine.
5. Ensure timing marks on camshaft sprockets and marks on timing belt rear plates are aligned. (Scheme 19) If timing marks do not align, turn crankshaft one revolution (360-degrees) and realign marks.
6. Turn crankshaft pulley approximately 50-degrees clockwise, and align timing mark on crankshaft pulley with center of crankshaft pulley bolt and center of No. 2 timing belt idler pulley bolt. (Scheme 20) Remove crankshaft pulley bolt. DO NOT turn crankshaft. Remove timing belt tensioner and dust boot. (Scheme 16)
7. Using Variable Pin Wrench Set (09960-10010), loosen tension between left and right camshaft timing sprockets by slightly turning RH camshaft timing pulley clockwise. Remove timing belt from camshaft sprockets. Remove 4 bolts each and remove camshaft timing sprockets. Remove generator. Remove power steering pump pulley. Remove drive belt tensioner. (Scheme 17)
8. Using a suitable puller, remove crankshaft pulley. DO NOT turn crankshaft. Remove No. 1 (lower) timing belt cover. (Scheme 17) Remove timing belt guide and timing belt cover spacer. Remove timing belt. Remove No. 1 and 2 timing belt idler pulleys. If necessary, remove crankshaft sprocket using a suitable puller.

1. Using a hammer and suitable driver, align keyway in crankshaft sprocket with key in crankshaft, and install sprocket so flange on sprocket is facing toward cylinder block (if removed). DO NOT turn crankshaft.
2. Apply Loctite 242 to threads of idler pulley pivot bolts. Install No. 1 and 2 timing belt idler pulleys, and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000). Ensure idler pulleys move freely. Ensure all sprockets and pulleys are clean and dry.
3. Align timing belt marks with marks on sprockets and install timing belt onto crankshaft sprocket and idler pulleys. Install timing belt cover spacer and gasket. Install timing belt guide. (Scheme 17) Install No. 1 timing belt cover. Using a hammer and suitable driver, install crankshaft pulley. Install drive belt tensioner. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000). Ensure crankshaft pulley timing mark is still in alignment with the centers of pulley bolts. (Scheme 14)
4. Install generator. Install power steering pump pulley. Align knock pin and install LH camshaft timing sprocket so the "L" on sprocket is facing outward. Align knock pin and install RH camshaft timing sprocket so the "R" is facing outward. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000). NOTE: Ensure camshaft sprocket identification mark faces forward. Identification mark is located on front of camshaft sprocket. Right camshaft sprocket contains an "R" identification mark, and left camshaft sprocket contains an "L" identification mark.
5. Align marks and install timing belt onto LH camshaft sprocket. Using Variable Pin Wrench Set (09960-10010), slightly turn LH camshaft sprocket until there is belt tension between crankshaft sprocket and LH camshaft sprocket. Align marks and install timing belt onto RH camshaft sprocket. Install timing belt tensioner and dust boot. Using pliers, remove the hexagon (Allen) wrench from tensioner.
6. Install crankshaft pulley bolt. Ensure all timing marks are still in alignment. Slowly rotate crankshaft clockwise 2 revolutions and recheck all timing marks for proper alignment. (Scheme 19) If timing marks do not align, remove timing belt and reinstall. Tighten crankshaft pulley bolt to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000). CAUTION: Always rotate crankshaft clockwise as viewed from front of engine. DO NOT rotate crankshaft counterclockwise.
7. Install No. 1 drive belt idler pulley. Insert crankshaft position sensor wire between idler pulley and oil pump. Install A/C compressor. Install No. 2 timing belt cover. Install No. 3 (RH) timing belt cover and gasket. Install 2 power steering air hoses to clamp on No. 3 (RH) timing belt cover. Install No. 3 (LH) timing belt cover and gasket. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000).
8. Insert camshaft position sensor wire through hole in No. 3 (LH) timing belt cover. Connect camshaft position sensor connector. Install harness wires to retaining clamps on timing belt covers.
9. Connect water by-pass hoses to by-pass pipe. Install water by-pass pipe to No. 3 (LH) timing belt cover. Install No. 2 drive belt idler pulley and cover plate. (Scheme 16) Install radiator and cooling fans assembly.
10. Install drive belt. Install intake air duct and air cleaner assembly. Fill engine with coolant. Start engine and check for coolant leaks. Bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-131978-S36299518652002010500000) under ADJUSTMENTS. Install engine "V" bank and side covers. Install engine under cover.

Removal

Remove camshafts. See CAMSHAFT . Note location of valve lifters and adjusting shims for installation reference. Carefully remove valve lifters and adjusting shims from cylinder head. DO NOT allow adjusting shims to drop into engine through cylinder head.

To install, reverse removal procedure. Ensure components are installed in original location. If camshaft, adjusting shims or valve lifters require replacement, check valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

Remove transmission, drive plate, and front and rear drive plate spacers. Using a knife, cut seal lip from oil seal. Carefully pry crankshaft rear oil seal from rear seal housing. DO NOT damage sealing surface.

1. Ensure all sealing surfaces are clean. Apply grease to lip of NEW crankshaft rear oil seal. Using a hammer and Oil Seal Installer (09223-56010), install NEW rear crankshaft oil seal in seal housing until seal is even with seal housing surface.
2. Apply Three Bond 1234 to threads of drive plate bolts. Install drive plate with front and rear spacers on crankshaft and tighten bolts to specification in 2 steps. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000) . Install transmission to engine. Apply Three Bond 1234 to threads of torque converter bolts and install the Black colored bolt first. Install flywheel access cover. To install remaining components, reverse removal procedure.

1. Drain cooling system. Remove timing belt. See «TIMING BELT»(ref-131978-S15835946542002010500000) . Remove No. 2 idler pulley. Remove throttle body.
2. Remove water intake housing assembly from water pump. Remove "O" ring from water by-pass pipe on intake housing. Remove by-pass hose from water intake housing. Remove 5 bolts and 2 nuts. Remove water pump and gasket.

Scheme 21

1. Ensure all sealing surfaces are clean. Install NEW "O" ring on water by-pass pipe on intake housing. Coat "O" ring with soapy water and install water by-pass pipe to water pump. Using a NEW gasket, install water pump. Install retaining bolts and nuts, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000).
2. Apply a continuous bead of silicone sealant to groove in mounting surface of water intake housing. Install NEW "O" ring on water intake housing, and lubricate "O" ring with soapy water.
3. Push water intake housing end into water pump opening. Connect by-pass hose to water intake housing. Install water intake housing assembly. Install the 2 water intake housing bolts in their correct location. (Scheme 22) Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000).
4. To install remaining components, reverse removal procedure. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-131978-S36299518652002010500000).

1. Remove engine. See «ENGINE»(ref-131978-S01920053232002010500000). Remove No. 2 oil pan retaining bolts and nuts. (Scheme 23)
2. Using Seal Cutter (09032-00100), separate No. 2 from No. 1 oil pan. Carefully tap seal cutter around No. 2 oil pan to loosen seal. DO NOT damage sealing surfaces. Remove No. 2 oil pan.
3. Remove bolts and nuts, and remove baffle plate. (Scheme 23) Note location of No. 1 oil pan nuts and bolts. Remove No. 1 oil pan nuts and bolts. Using a screwdriver, pry evenly between oil pan and cylinder block, and remove No. 1 oil pan.

Scheme 22

Scheme 23

Scheme 24

Scheme 25

1. Ensure sealing surfaces are clean and dry. Apply a continuous bead of silicone sealant onto sealing surface of No. 1 oil pan, inside of bolt holes. Install No. 1 oil pan. Install No. 1 oil pan nuts and bolts in their correct location. (Scheme 24)or (Scheme 25). See «LS430 NO. 1 OIL PAN BOLT SPECIFICATIONS»(ref-131978-S06843303952002010500000) table. Ensure clearance between rear ends of oil pan and cylinder block is.008" (0.2 mm) or less to prevent oil pan from being stretched out of shape. (Scheme 25) Tighten No. 1 oil pan nuts and bolts in several steps to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000). LS430 NO. 1 OIL PAN BOLT SPECIFICATIONS Bolt (1) Head Size mm Length - In. (mm) "A" 10 0.79 (20) "B" 10 1.38 (35) "C 12 2.36 (60) "D" 12 0.98 (25) (1) (Scheme 25)
2. Install baffle plate. On GS430 models, install baffle plate nuts and bolts in their correct location. see scheme 28 On LS430 models, install baffle plate nuts and bolts. On all models, tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000).
3. Apply a continuous bead of silicone sealant onto sealing surface of No. 2 oil pan, inside of bolt holes. Install No. 2 oil pan nuts and bolts, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000).

1. Ensure sealing surfaces are clean. Install NEW "O" ring on cylinder block. Apply a continuous bead of silicone sealant on oil pump body sealing surface, inside of bolt holes.
2. Install oil pump. Ensure teeth on drive rotor engage with teeth on crankshaft. Install bolts. DO NOT reuse stud bolt. Ensure proper bolts are installed in specified areas. see scheme 39 Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(ref-131978-S04317680092002010500000).
3. To install remaining components, reverse removal procedure. Ensure proper oil pan installation procedure is used. See «OIL PAN»(ref-131978-S38792457752002010500000) under REMOVAL & INSTALLATION. Fill engine with oil.

Scheme 26