Engine Mechanical (4.7L V8): Removal & Installation Lexus LX J100

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.

Installation

1. To install, reverse removal procedure. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-3005-S05931701232000041700000) . Ensure reference marks on drive shaft flanges are aligned. If removed, apply Loctite to threads of flywheel/drive plate bolts before installing. Tighten flywheel/drive plate bolts to specification in a crisscross pattern. See «TORQUE SPECIFICATIONS»(ref-3005-S05931701232000041700000) . If torque converter bolts were removed, apply Loctite to bolt threads before installing. Install Black torque converter bolt before installing any other torque converter bolts.
2. Apply light coat of engine oil to tip of pipe on fuel filter to allow for ease of disconnect fitting, and fuel inlet hose installation. Using NEW retainer, install fuel inlet hose on fuel filter until "click" sound is heard. DO NOT reuse old retainer. Pull on fuel inlet hose to ensure fuel inlet hose is properly locked on fuel filter.
3. Use NEW gaskets when installing transfer case shift lever and front exhaust pipes. Install remaining components. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-3005-S17682609922000041700000) .

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-3005-S24472918612000041700000). Disconnect timing belt from camshaft sprockets and supporting timing belt when servicing cylinder head. Disconnect timing belt from camshaft sprockets. See «TIMING BELT»(ref-3005-S06637290162000041700000). CAUTION: DO NOT rotate engine or allow timing belt to become disengaged from crankshaft sprocket when timing belt is removed from camshaft sprockets.
2. Remove bolt, stud bolt and camshaft position sensor located just below camshaft sprocket on driver-side camshaft. (Scheme 14)
3. Using spanner wrench in holes on front of camshaft sprocket, hold camshaft sprocket while removing camshaft sprocket bolt. Remove camshaft sprockets from camshafts.
4. Remove power steering pump with hoses attached, and secure aside. Raise and support vehicle. Remove front exhaust pipes. These are the exhaust pipes with catalytic converters that fit between exhaust manifolds and center exhaust pipe.
5. Remove transmission dipstick and dipstick tube with "O" ring. Disconnect electrical connector at each ignition coil. Remove bolts and ignition coils from valve covers.
6. Remove intake manifold cover located on top of engine, above intake manifold. Intake manifold cover may also be referred to as "V" bank cover. Remove bolts and timing belt rear plate from front of each cylinder head. (Scheme 15) CAUTION: Use care when disconnecting fuel inlet hose from fuel filter, as some residual fuel pressure may still exist in fuel system.
7. Depress both sides of retainer and pull fuel inlet hose with disconnect fitting from fuel filter. see scheme 9 Disconnect fuel return hose from fuel pressure regulator on fuel rail.
8. Disconnect accelerator cable at throttle body and engine. Disconnect necessary hoses, electrical connectors, coolant hoses and vacuum hoses for removal of intake manifolds and cylinder heads.
9. Disconnect coolant by-pass hoses at front coolant by-pass joint. Disconnect engine wire clamps from throttle body and fuel rail. Remove bolts and disconnect engine wiring harness protector from rear coolant by-pass joint, passenger-side cylinder head and intake manifold. (Scheme 15)
10. Disconnect ground straps at both cylinder heads. Disconnect engine wire harness from engine hanger and wiring bracket. Remove bolts and EVAP pipe from rear of intake manifold. (Scheme 15)
11. Remove bolts and intake manifold cover brackets from both sides of upper intake manifold. Remove lower intake manifold-to-cylinder head bolts/nuts. Remove upper and lower intake manifolds with fuel injectors and fuel rails as an assembly. Remove gaskets for lower intake manifold.
12. Disconnect coolant by-pass hose at coolant inlet housing assembly. (Scheme 15) Remove bolts and coolant inlet housing assembly with "O" ring.
13. Remove nuts, front coolant by-pass joint, rear coolant by-pass joint and gaskets. (Scheme 15) Remove engine oil dipstick, dipstick tube and "O" ring (if necessary). Remove camshafts. See «CAMSHAFT»(ref-3005-S32568546162000041700000). CAUTION: Cylinder head bolts must be removed in proper sequence to prevent cylinder head warpage. When removing cylinder head bolts, ensure washers on cylinder head bolts do not fall into area "A" on cylinder head. (Scheme 16) If washer falls into area "A" on cylinder head, washer may fall into oil pan.
14. Remove cylinder head bolts with washers in sequence using several steps. (Scheme 17) Remove cylinder head and gasket. DO NOT drop valve lifter and adjusting shim from cylinder head.
15. If removing valve lifters and adjusting shims from cylinder head, ensure component location is marked for installation reference. Remove bolts, heat insulator, nuts, exhaust manifold and gasket from cylinder head (if necessary).
16. If removing fuel rails with fuel injectors from lower intake manifold, remove fuel return pipe-to-fuel rail clamp bolt, and separate clamp on fuel return pipe from rear of driver-side fuel rail. (Scheme 18)
17. Remove front fuel pipe clamp bolt from clamp at center of front fuel pipe. Remove front fuel pipe-to-fuel rail union bolt with gaskets, and remove front fuel pipe from front of both fuel rails. (Scheme 18) CAUTION: When removing fuel rails, DO NOT allow fuel injectors to fall from fuel rails.
18. Remove fuel rail-to-lower intake manifold nuts. Remove fuel rails with fuel injectors as an assembly from lower intake manifold. Note direction of spacer installation on lower intake manifold for installation reference. Remove spacers and insulators from lower intake manifold. Remove fuel injectors from fuel rail. Remove "O" rings and grommets from fuel injector.

Removal & Installation (Oil Pump Installed)

1. Remove timing belt and crankshaft sprocket. See «TIMING BELT»(ref-3005-S06637290162000041700000) . Using a knife, cut seal lip from seal. Pry seal from oil pump body. DO NOT damage sealing surfaces.
2. To install, apply grease to lip of new seal. Using hammer and Seal Installer (SST 09316-00011), 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 09316-00011), install new seal until seal surface is even with oil pump body. Apply grease to seal lip of seal.

Scheme 19

Scheme 20

1. Raise and support vehicle. Remove lower engine cover. Drain cooling system. Remove battery clamp cover. Disconnect negative battery cable. Remove air cleaner assembly with air intake hose that goes to throttle body.
2. Remove bolts, cap nuts and remove intake manifold cover located on top of engine, above intake manifold. Intake manifold cover may also be referred to as "V" bank cover. Remove fuel return hose. Remove coolant reservoir. Remove radiator and fan shroud.
3. Rotate accessory drive belt tensioner counterclockwise, as viewed from front of engine, to release tension on accessory drive belt. Remove accessory drive belt. Remove cooling fan and cooling fan pulley.
4. Remove bolt, cover plate and accessory drive belt idler pulley. (Scheme 19) Remove bolts/nuts and No. 3 timing belt cover from front of passenger-side camshaft. (Scheme 19)
5. Disconnect engine wire clamps for access to No. 3 timing belt cover at front of driver-side camshaft. (Scheme 19) Remove bolts/nuts for No. 3 timing belt cover at front of driver-side camshaft. Disconnect wire from camshaft position sensor from wire clamp on No. 3 timing belt cover. Disconnect electrical connector for camshaft position sensor. Remove grommet for wire for camshaft position sensor from No. 3 timing belt cover.
6. Remove No. 3 timing belt cover from driver-side camshaft. Remove bolts and oil cooler pipe. Remove bolts and No. 2 timing belt cover. (Scheme 19) Remove A/C compressor with hoses attached, and secure aside. Remove bolts/nuts and cooling fan bracket. (Scheme 19)
7. Using Pulley Holder (SST 09213-70010) and Handle (SST 09330-00021), hold crankshaft pulley. Loosen crankshaft pulley bolt. CAUTION: If reusing timing belt, ensure timing marks or installation marks are on timing belt at timing mark at each camshaft sprocket. (Scheme 20) If timing marks or installation marks are not apparent, place timing mark or installation mark on timing belt at timing mark on camshaft sprocket for installation reference and to indicate direction of timing belt installation on camshaft sprockets.
8. Using crankshaft pulley bolt, rotate crankshaft pulley clockwise viewed from front of engine so crankshaft pulley groove aligns with "0" mark on No. 1 (lower) timing belt cover. Ensure timing marks on camshaft sprockets align with timing marks on timing belt rear plates and timing marks or installation marks on timing belt align with timing mark on camshaft sprocket. (Scheme 20) If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley groove with "0" mark on No. 1 (lower) timing belt cover. CAUTION: Ensure crankshaft is properly positioned before removing timing belt to prevent valves from contacting pistons. DO NOT allow engine to rotate when removing crankshaft pulley bolt.
9. Using crankshaft pulley bolt, rotate crankshaft clockwise, as viewed from front of engine, about 50 degrees so crankshaft pulley groove aligns with center of bolt on No. 2 idler pulley. (Scheme 21) This will prevent valves from contacting pistons. Remove crankshaft pulley bolt. NOTE: If replacing only the timing belt tensioner, use string to secure timing belt to passenger-side camshaft sprocket. Also, place reference mark on one tooth of passenger-side camshaft sprocket. Place reference mark on timing belt at each side of reference mark placed on tooth of passenger-side camshaft sprocket.
10. Alternately loosen bolts, and remove timing belt tensioner and dust boot. (Scheme 19) Using spanner wrench in holes on front of passenger-side camshaft sprocket, slightly rotate passenger-side camshaft sprocket clockwise, as viewed from front of engine, to release tension on timing belt. Remove timing belt from camshaft sprockets. If removing camshaft sprockets, use spanner wrench on front of camshaft sprocket to hold camshaft sprocket. Remove bolt and camshaft sprocket.
11. Remove generator. Remove bolts/nuts and accessory drive belt tensioner. CAUTION: DO NOT allow engine to rotate when removing crankshaft pulley.
12. Using puller, remove crankshaft pulley. Remove bolts and No. 1 timing belt cover. Note direction of timing belt guide installation for installation reference. (Scheme 19) Remove timing belt guide and timing belt cover spacer. CAUTION: If reusing timing belt, ensure timing mark or installation mark exists on timing belt at dot on crankshaft sprocket. (Scheme 20) If timing mark or installation mark is not apparent, place timing mark or installation mark on timing belt at dot on crankshaft sprocket.
13. Remove timing belt from crankshaft sprocket. Remove No. 1 and 2 idler pulleys (if necessary). (Scheme 19) If removing crankshaft sprocket, use puller to remove crankshaft sprocket. DO NOT allow engine to rotate when removing crankshaft sprocket.

Scheme 21

Removal

Remove camshaft. See CAMSHAFT . Note location of adjusting shims and valve lifters for installation reference. Remove valve lifters and adjusting shims from cylinder head.

To install, reverse removal procedure. Ensure components are installed in original location and valve lifter rotates smoothly in cylinder head. If camshaft, adjusting shim or valve lifter are replaced, check valve clearance. See VALVE CLEARANCE under ADJUSTMENTS.

Scheme 22

Scheme 23

Scheme 24

1. Remove intake manifold cover located on top of engine, above intake manifold. Intake manifold cover may also be referred to as "V" bank cover. Drain cooling system if any coolant hoses must be disconnected for access to valve covers.
2. Remove air cleaner assembly with throttle body air intake hose. Remove bolts/nuts and No. 3 timing belt cover from front of each cylinder head at each camshaft. (Scheme 19) Disconnect electrical connector at each ignition coil. Remove bolts and ignition coils from valve covers.
3. Remove transmission oil dipstick. Disconnect necessary hoses and engine wiring brackets for access to valve covers. Remove bolts, seal washers, valve covers and gaskets.
4. Remove timing belt and camshaft sprockets. See «TIMING BELT»(ref-3005-S06637290162000041700000). Remove bolts and timing belt rear plate from front of each cylinder head. (Scheme 15) Remove camshaft housing plug from front of cylinder head and semi-circular plugs from rear of cylinder head. see scheme 17 CAUTION: Crankshaft must be properly positioned before removing camshafts to prevent the valves from contacting the pistons when removing camshafts.
5. Using crankshaft pulley bolt, rotate crankshaft clockwise, as viewed from front of engine, so crankshaft pulley groove aligns with center of bolt on No. 2 idler pulley. (Scheme 21) This will prevent valves from contacting pistons.
6. Use wrench to rotate exhaust camshaft until service bolt hole on camshaft sub-gear is facing upward. (Scheme 22) Using a 6 x 1.0 x 18-mm service bolt, secure camshaft sub-gear on exhaust camshaft to main gear on exhaust camshaft. (Scheme 22)
7. On passenger-side camshaft applications, rotate exhaust camshaft so timing marks (one dot) on main gear on camshaft is at approximately 10 degrees. (Scheme 23) On driver-side camshaft applications, rotate exhaust camshaft so timing marks (2 dots) on main gear on camshaft are aligned. (Scheme 23) NOTE: All camshaft bearing caps except front camshaft bearing cap are numbered for location on top of camshaft bearing cap. Camshaft bearing cap is also stamped with either an "I" for intake camshaft or an "E" for exhaust camshaft. Arrow on top of camshaft bearing cap must point toward front of engine. (Scheme 24) Ensure camshaft bearing caps are installed in correct location.
8. On all applications, note location of camshaft bearing caps, as camshaft bearing caps are numbered for location on top of camshaft bearing cap. Camshaft bearing cap is also stamped with either an "I" for intake camshaft or an "E" for exhaust camshaft. Arrow on top of camshaft bearing cap must point toward front of engine. (Scheme 24) CAUTION: Before removing camshaft bearing cap bolts, ensure service bolt is installed to hold torsional spring force of camshaft sub-gear. (Scheme 22) Ensure camshaft bearing cap bolts are removed in proper sequence to prevent damage to cylinder head and camshaft thrust surfaces. Note length and location of camshaft bearing cap bolts for installation reference.
9. Remove camshaft bearing cap bolts in sequence using several steps. (Scheme 25) Remove oil feed pipe, camshaft bearing caps and camshafts.
10. If disassembling exhaust camshaft, mount hexagonal area of camshaft in soft-jaw vise. Using spanner wrench, rotate camshaft sub-gear clockwise and remove service bolt. (Scheme 26) Remove snap ring, wave washer, camshaft sub-gear and camshaft gear spring from exhaust camshaft. see scheme 17 Remove oil seal from intake camshaft.

Scheme 25

Scheme 26

1. Remove transmission and flywheel/drive plate. See TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Cut seal lip from crankshaft rear oil seal. Pry crankshaft rear oil seal from rear oil seal housing. DO NOT damage rear oil seal housing and crankshaft surfaces.
2. To install, coat lip of crankshaft rear oil seal with grease. Using hammer and Oil Seal Installer (SST 09223-56010), install new crankshaft rear oil seal in rear oil seal housing until oil seal is even with surface of rear oil seal housing.
3. To install remaining components, reverse removal procedure. Apply Loctite or equivalent to threads of flywheel/drive plate bolts before installing. Tighten flywheel/drive plate bolts to specification in a crisscross pattern. See «TORQUE SPECIFICATIONS»(ref-3005-S05931701232000041700000) .

1. Drain cooling system. Remove timing belt and No. 2 idler pulley. See «TIMING BELT»(ref-3005-S06637290162000041700000).
2. Disconnect coolant by-pass hose at coolant inlet housing assembly. (Scheme 15) Remove bolts and coolant inlet housing assembly with "O" ring. Remove "O" ring from coolant inlet housing assembly.
3. Water pump is located on front of cylinder block, just below camshaft sprockets. (Scheme 15) Remove bolts, stud bolt, nut, water pump and gasket from front of cylinder block. Remove "O" ring from end of coolant by-pass pipe where by-pass pipe fits into water pump. Coolant by-pass pipe is located on top of cylinder block, and fits into rear of water pump. (Scheme 15)

1. Install NEW "O" ring onto end of coolant by-pass pipe. Coat "O" ring with soapy water solution. Using NEW gasket, install water pump onto coolant by-pass pipe and front of cylinder block. Install and tighten bolts, stud bolt and nut for water pump to specification. See «TORQUE SPECIFICATIONS»(ref-3005-S05931701232000041700000).
2. Install NEW "O" ring and apply sealant to groove on coolant inlet housing assembly. see scheme 18 Coat "O" ring with soapy water solution. Install coolant inlet housing assembly. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-3005-S05931701232000041700000)
3. Ensure proper procedure is followed when installing No. 2 idler pulley and timing belt. See «TIMING BELT»(ref-3005-S06637290162000041700000). Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-3005-S17682609922000041700000).

1. Remove engine for servicing of oil pan. Remove engine. See «ENGINE»(ref-3005-S39727714892000041700000). Remove engine oil dipstick, dipstick tube and "O" ring.
2. To remove No. 2 oil pan, remove No. 2 oil pan bolts/nuts. Install Seal Cutter (SST 09032-00100) between No. 1 and 2 oil pans. Using hammer, tap seal cutter along sides of No. 2 oil pan surface to loosen seal between No. 1 and 2 oil pans. DO NOT damage sealing surfaces. Remove No. 2 oil pan.
3. To remove No. 1 oil pan, remove bolts/nuts and baffle plate. (Scheme 27) Remove bolts/nuts for No. 1 oil pan. Remove No. 1 oil pan by prying between cylinder block and No. 1 oil pan at designated areas. (Scheme 28) DO NOT damage sealing surfaces. Remove bolts/nuts oil pump pick-up tube and gasket (if necessary).

Scheme 27

Scheme 28

1. Using NEW gasket, install oil pump pick-up tube (if removed). Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-3005-S05931701232000041700000). Ensure all sealing surfaces are clean.
2. Apply a.12-.20" (3.0-5.0 mm) diameter bead of sealant at specified areas on No. 1 oil pan. (Scheme 29) Install No. 1 oil pan with bolt/nuts loosely installed. Ensure proper length bolts are installed in proper areas. (Scheme 30)
3. Check clearance between cylinder block and both ends of No. 1 oil pan. (Scheme 30) Clearance must be less than.008" (.20 mm). If clearance is more than.008" (.20 mm), No. 1 oil pan will be stretched. Position No. 1 oil pan so clearance is less than.008" (.200 mm).
4. Tighten bolts/nuts for No. 1 oil pan to specification. See «TORQUE SPECIFICATIONS»(ref-3005-S05931701232000041700000). Install baffle plate. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-3005-S05931701232000041700000).
5. Apply a.12-.20" (3.0-5.0 mm) diameter bead of sealant at specified areas on No. 2 oil pan. (Scheme 29) Install No. 2 oil pan. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-3005-S05931701232000041700000).
6. To install remaining components, reverse removal procedure. Use NEW "O" ring coated with soapy water solution when installing engine oil dipstick.

Scheme 29

Scheme 30

Removal & Disassembly

1. Remove No. 1 and 2 oil pans and oil pump pick-up tube. See «OIL PAN»(ref-3005-S23740480152000041700000) under REMOVAL & INSTALLATION. Remove timing belt, No. 1 and 2 idler pulleys, and crankshaft pulley. See «TIMING BELT»(ref-3005-S06637290162000041700000) under REMOVAL & INSTALLATION.
2. Disconnect coolant hose at oil cooler. Remove bolts/nuts, oil filter mounting bracket and gasket from engine. Remove bolt and crankshaft position sensor from side of oil pump body. (Scheme 31)
3. Note location of oil pump-to-cylinder block bolts for installation reference. Remove oil pump-to-cylinder block bolts. Remove oil pump by prying at specified locations. (Scheme 32) DO NOT damage sealing surfaces. Remove"O" ring from front of cylinder block.
4. Remove snap ring, retainer, relief valve spring and relief valve. (Scheme 33) Remove screws, oil pump body cover and rotors. Remove crankshaft front seal (if necessary).

Scheme 31

Scheme 32

Scheme 33

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure drive and driven rotors are installed in oil pump body, with mark facing upward. see scheme 51 Tighten screws for oil pump body cover to specification. See «TORQUE SPECIFICATIONS»(ref-3005-S05931701232000041700000).
2. If installing crankshaft front seal, apply grease to seal lip of NEW seal. Using hammer and Seal Installer (SST 09316-00011), install seal until seal surface is even with oil pump body.
3. To install, apply sealant at designated areas on rear of oil pump body. (Scheme 34) DO NOT allow sealant to enter oil passages on oil pump body. Install NEW "O" ring on front of cylinder block.
4. Install oil pump body on cylinder block. Ensure teeth on drive rotor engage with proper areas on crankshaft. (Scheme 34) Install and tighten oil pump-to-cylinder block bolts to specification. See «TORQUE SPECIFICATIONS»(ref-3005-S05931701232000041700000).
5. To install remaining components, reverse removal procedure. Ensure proper procedures are followed when installing timing belt and oil pans. Use NEW gasket when installing oil filter mounting bracket. Tighten bolts/nuts for oil filter mounting bracket to specification. See «TORQUE SPECIFICATIONS»(ref-3005-S05931701232000041700000).

Scheme 34

1. Oil cooler is mounted on front of engine, near oil filter. see scheme 47 Drain cooling system. Remove oil filter.
2. Disconnect coolant hoses at oil cooler. Remove oil cooler union bolt and washer from oil cooler. Oil cooler union bolt is located at center of oil cooler and contains the threads that oil filter screws onto. Remove oil cooler and "O" ring from oil filter mounting bracket.

1. To install, reverse removal procedure using NEW "O" ring. Apply engine oil to threads and bolt-to-oil cooler contact surfaces on oil cooler union bolt before installing. Tighten oil cooler union bolt to specification. See «TORQUE SPECIFICATIONS»(ref-3005-S05931701232000041700000) .
2. Adjust engine oil level as necessary. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-3005-S17682609922000041700000) under REMOVAL & INSTALLATION.