Engine Mechanical: Diagnosis Lexus LX J100 рестайлинг

INSPECTION

HINT

This check is used only to determine whether or not the idle CO/HC complies with regulations.

Scheme 5

Scheme 6

1. INITIAL CONDITIONS The engine is at normal operating temperature. Air cleaner is installed. All pipes and hoses of the air induction system are connected. All accessories are switched OFF. All vacuum lines are properly connected. HINT: All vacuum hoses should be properly connected. SFI system wiring connectors are fully plugged. Ignition timing is set correctly. Transmission is in neutral range. Tachometer and CO/HC meter are calibrated by hand.
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST 40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT IDLE AND/OR 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.
6. TROUBLESHOOTING If the CO/HC concentration does not comply with the regulations, perform troubleshooting in the order in (Scheme 6).

HINT

If there is a lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.

Scheme 7

1. WARM UP AND STOP ENGINE Allow the engine to warm up to the normal operating temperature.
2. REMOVE SPARK PLUGS (See «IGNITION SYSTEM» )
3. CHECK CYLINDER COMPRESSION PRESSURE Insert a compression gauge into the spark plug hole. Fully open the throttle. While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain the engine speed at 250 rpm or more. Repeat steps ( a ) to ( c ) for each cylinder. NOTE: This measurement must be done as quickly as possible. Compression pressure: 1,324 kPa (13.5 kgf/cm2, 192 psi) or more Minimum pressure: 981 kPa (10.0 kgf/cm2, 142 psi) Difference between each cylinder: 98 kPa (1.0 kgf/cm2, 14 psi) or less If the cylinder compression in one or more cylinders is lower than the specification, pour a small amount of engine oil into the cylinder through the spark plug hole and repeat steps ( a ) to ( c ) for the cylinders. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damage. If the pressure stays low, a valve may be sticking or the seating is improper, or there may be leakage past the gasket.
4. REINSTALL SPARK PLUGS (See «IGNITION SYSTEM» )

HINT

Inspect and adjust the valve clearance when the engine is cold.

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

1. DRAIN ENGINE COOLANT
2. REMOVE BATTERY CLAMP COVER
3. REMOVE V-BANK COVER
4. REMOVE AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY
5. REMOVE NO. 3 TIMING BELT COVERS (See «REMOVAL» )
6. REMOVE IGNITION COILS (See «REMOVAL» )
7. REMOVE RH CYLINDER HEAD COVER Remove the 9 bolts, the 9 seal washers and the cylinder head cover.
8. REMOVE LH CYLINDER HEAD COVER Remove the oil dipstick for the transmission. Disconnect the PCV hose. Disconnect the engine wire clamp from the wire bracket on the cylinder head cover. Remove the 9 bolts, the 9 seal washers and the cylinder head cover.
9. SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with timing mark "0" of the No. 1 timing belt cover. Check that the timing marks of the camshaft timing pulleys and that of the timing belt rear plates are aligned. If not, turn the crankshaft 1 revolution (360°) and align the mark (Scheme 9)
10. INSPECT VALVE CLEARANCE Check only the valves indicated. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake 0.15 - 0.25 mm (0.006 - 0.010 in.) Exhaust 0.25 - 0.35 mm (0.010 - 0.014 in.) Turn the crankshaft 1 revolution (360°) and align the mark (Scheme 10)(See procedure in step 9 ). Check only the valves indicated (Scheme 10) Measure the valve clearance (See procedure in step ( a )).
11. ADJUST VALVE CLEARANCE Remove the timing belt (See «REMOVAL» ). Remove the camshafts (See «DISASSEMBLY» ). Remove the valve lifter and adjusting shim. Determine the replacement adjusting shim size according to the following Formula and Tables: Using a micrometer, measure the thickness of the removed shim. Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T........... Thickness of removed shim A........... Measured valve clearance N........... Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 in.)) Exhaust: N = T + (A - 0.30 mm (0.012 in.)) Select a new shim with the closest thickness as close as possible to the calculated value. HINT: Shims are available in 41 increments of 0.020 mm (0.0008 in.) from 2.00 mm (0.0787 in.) to 2.80 mm (0.1102 in.). Place a new adjusting shim on the valve. Place the valve lifter. Reinstall the camshafts (See «REASSEMBLY» ). Reinstall the timing belt (See «INSTALLATION» ). Recheck the valve clearance.
12. REINSTALL CYLINDER HEAD COVERS
13. REINSTALL IGNITION COILS
14. REINSTALL NO. 3 TIMING BELT COVERS (See «INSTALLATION» )
15. REINSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY
16. REFILL WITH ENGINE COOLANT
17. START ENGINE AND CHECK FOR LEAKS
18. RECHECK ENGINE COOLANT LEVEL
19. REINSTALL V-BANK COVER
20. REINSTALL BATTERY CLAMP COVER

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

1. REMOVE BATTERY CLAMP COVER
2. REMOVE INTAKE AIR CONNECTOR
3. REMOVE V-BANK COVER
4. WARM UP ENGINE Allow the engine to warm up to the normal operating temperature.
5. CONNECT LEXUS HAND-HELD TESTER OR OBD II SCAN TOOL Connect the LEXUS hand-held tester or OBD II scan tool to the DLC3. Please refer to the hand-held tester or OBD II scan tool operator's manual for further details.
6. CONNECT TIMING LIGHT TO ENGINE Connect the tester probe of a timing light to the wire of the ignition coil connector for No. 1 cylinder.
7. CHECK IDLE SPEED Race the engine speed at 2,500 rpm for approx. 90 seconds. Check the idle speed. Idle speed: 700 +/- 50 rpm
8. INSPECT IGNITION TIMING Using SST, connect TC and E1 of the DLC1. SST 09843-18020 Using a timing light, check the ignition timing. Ignition timing: 5 - 15° BTDC @ idle (Transmission in neutral position) Remove SST from the DLC1. SST 09843-18020
9. DISCONNECT TIMING LIGHT FROM ENGINE
10. DISCONNECT LEXUS HAND-HELD TESTER OR OBD II SCAN TOOL
11. REINSTALL V-BANK COVER
12. REINSTALL INTAKE AIR CONNECTOR
13. REINSTALL BATTERY CLAMP COVER

1. INITIAL CONDITIONS Engine is at normal operating temperature Air cleaner is installed All pipes and hoses of air induction systems are connected All accessories are switched OFF All vacuum lines are properly connected HINT: All vacuum hoses should be properly connected. SFI system wiring connectors are fully plugged Ignition timing is set correctly Transmission is in neutral position Air conditioning switches are OFF
2. CONNECT LEXUS HAND-HELD TESTER OR OBD II SCAN TOOL (See «IGNITION TIMING» )
3. INSPECT IDLE SPEED Race the engine speed at 2,500 rpm for approx. 90 seconds. Check the idle speed. Idle speed: 700 +/- 50 rpm If the idle speed is not as specified, check the air intake system.
4. DISCONNECT LEXUS HAND-HELD TESTER OR OBD II SCAN TOOL

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

1. REMOVE OIL PAN PROTECTOR
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT
4. REMOVE BATTERY CLAMP COVER
5. REMOVE V-BANK COVER Remove the fuel return hose from the V-bank cover. Remove the 2 bolt, 2 cap nuts and V-bank cover.
6. REMOVE AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY
7. REMOVE DRIVE BELT, FAN, FLUID COUPLING AND FAN PULLEY Loosen the 4 nuts holding the fluid coupling to the fan bracket. Remove the generator drive belt. (See «GENERATOR» ) Remove the 4 nuts, the fan, the fluid coupling assembly and the fan pulley.
8. REMOVE RADIATOR ASSEMBLY (See «REMOVAL» )
9. REMOVE DRIVE BELT IDLER PULLEY Remove the pulley bolt, the cover plate and the idler pulley.
10. REMOVE RH NO. 3 TIMING BELT COVER Remove the 3 bolts, the nut and the RH No. 3 timing belt cover.
11. REMOVE LH NO. 3 TIMING BELT COVER Disconnect the engine wire from the 2 wire clamps. Remove the 4 bolts and the nut. Disconnect the camshaft position sensor wire from the wire clamp on the LH No. 3 timing belt cover. Disconnect the sensor connector from the connector bracket. Disconnect the sensor connector. Remove the wire grommet from the LH No. 3 timing belt cover. Remove the LH No. 3 timing belt cover. Remove the oil cooler pipe and the 2 bolts.
12. REMOVE NO. 2 TIMING BELT COVER Remove the 2 bolts and the No. 2 timing belt cover.
13. DISCONNECT A/C COMPRESSOR FROM ENGINE (See «REMOVAL» )
14. REMOVE FAN BRACKET Remove the 2 bolts, the 2 nuts and the fan bracket.
15. IF RE-USING TIMING BELT, CHECK INSTALLATION MARKS ON TIMING BELT Check that there are 3 installation marks on the timing belt as turning the crankshaft pulley (Scheme 28) HINT: If the installation marks are disappeared, place a new installation mark on the timing belt before removing each part.
16. LOOSEN CRANKSHAFT PULLEY BOLT Using SST, loosen the pulley bolt. SST 09213-70011 (90105-70020), 09330-00021
17. SET NO. 1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley and align its groove with the timing mark "0" of the No. 1 timing belt cover. Check that the timing marks of the camshaft timing pulleys and that of the timing belt rear plates aligned. If not, turn the crankshaft 1 revolution (360°). Remove the crankshaft pulley bolt. NOTE: Do not turn the crankshaft pulley.
18. REMOVE TIMING BELT TENSIONER HINT: When re-using timing belt: If the installation marks are disappeared, place 2 new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys before the removal. When replacing timing belt tensioner only: To avoid meshing of the timing pulley and the timing belt, secure one of them with string, and then place matchmarks on the timing belt and the RH camshaft timing pulley. Alternately loosen the 2 bolts, and remove the belt tensioner and the dust boot.
19. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS Using SST, loosen the tension spring between the LH and RH camshaft timing pulleys by slightly turning the LH camshaft timing pulley clockwise. SST 09960-10010 (09962-01000, 09963-01000) Disconnect the timing belt from the camshaft timing pulleys.
20. REMOVE CAMSHAFT TIMING PULLEYS Using SST, remove the bolt and the timing pulley. Remove the 2 timing pulleys. SST 09960-10010 (09962-01000,09963-01000)
21. REMOVE GENERATOR (See «REMOVAL & INSTALLATION» )
22. REMOVE DRIVE BELT TENSIONER Remove the bolt, 2 nuts and the belt tensioner.
23. REMOVE CRANKSHAFT PULLEY Using SST, remove the crankshaft pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05020, 09954-05021) NOTE: Do not turn the crankshaft pulley.
24. REMOVE NO. 1 TIMING BELT COVER Remove the 4 bolts and the timing belt cover.
25. REMOVE TIMING BELT GUIDE
26. REMOVE TIMING BELT COVER SPACER
27. REMOVE TIMING BELT HINT: If re-using the belt and the installation mark is disappeared from it, place a new installation mark on the timing belt to the match the dot mark on the crankshaft timing pulley.
28. REMOVE NO. 1 IDLER PULLEY AND NO. 2 IDLER PULLEY Using a 10 mm hexagon wrench, remove the bolt, the No. 1 idler pulley and the plate washer. Remove the bolt and the No. 2 idler pulley.
29. REMOVE CRANKSHAFT TIMING PULLEY Using SST, remove the timing pulley. SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05011, 09954-05021) NOTE: Do not turn the timing pulley.

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

1. INSPECT TIMING BELT NOTE: Do not bend, twist or turn the timing belt inside out. Do not allow the timing belt to contact with oil, water or steam. Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley. If there are any defects (Scheme 42), check these points: Premature parting Check for proper installation. Check the timing cover gasket for damage and proper installation. If the belt teeth are cracked or damaged, check if either camshaft is locked. If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and the water pump. Even if there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley. If there is noticeable wear on the belt teeth, check timing cover for damage and for foreign materials on the pull teeth. If necessary, replace the timing belt.
2. INSPECT IDLER PULLEYS Visually check the seal portion of the idler pulley for oil leakage. If leakage is found, replace the idler pulley. Check that the idler pulley turns smoothly. If necessary, replace the idler pulley.
3. INSPECT TIMING BELT TENSIONER Visually check the seal portion of the tensioner for oil leakage. HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right. If leakage is found, replace the tensioner. Hold the tensioner with both hands, and push the push rod strongly to check that it doesn't move. If the push rod moves, replace the tensioner. NOTE: Never hold the tensioner push rod facing downward. Measure the protrusion of the push rod from the housing end. Protrusion: 10.5 - 11.5 mm (0.413 - 0.453 in.) If the protrusion is not as specified, replace the tensioner.
4. INSPECT WATER PUMP (See «INSPECTION» )

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. INSTALL CRANKSHAFT TIMING PULLEY Align the timing pulley set key with the key groove of the pulley. Using SST and a hammer, tap in the timing pulley, facing the flange side inward. SST 09223-46011
2. INSTALL NO. 1 IDLER PULLEY AND NO. 2 IDLER PULLEY Apply adhesive 2 or 3 threads from the end of the pivot bolt. Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a 10 mm hexagon wrench, install the plate washer and the No. 1 idler pulley with the pivot bolt. Torque: 34.5 N.m (350 kgf.cm, 25 ft.lbf) Install the No. 2 idler pulley with the bolt. Torque: 34.5 N.m (350 kgf.cm, 25 ft.lbf) Check that the No. 1 and No. 2 idler pulley moves smoothly.
3. TEMPORARILY INSTALL TIMING BELT NOTE: The engine should be cold. Remove any oil or water on and clean the crankshaft pulley, the oil pump pulley, the water pump pulley, the No. 1 idler pulley and the No. 2 idler pulley. NOTE: Only wipe the pulleys; do not use any cleansing agent. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley. Install the timing belt on the crankshaft timing pulley, the No. 1 idler pulley and the No. 2 idler pulley.
4. INSTALL TIMING BELT COVER SPACER Install the gasket to the cover spacer. Install the cover spacer.
5. INSTALL TIMING BELT GUIDE Install the belt guide, facing the cup side outward.
6. INSTALL NO. 1 TIMING BELT COVER Install the timing belt cover with the 4 bolts.
7. INSTALL CRANKSHAFT PULLEY Align the pulley set key with the key groove of the crankshaft pulley. Using SST and a hammer, tap in the crankshaft pulley. SST 09223-46011
8. INSTALL DRIVE BELT TENSIONER Install the belt tensioner with the bolt and the 2 nuts. Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) HINT: Use a bolt of 106 mm (4.18 in.) in length.
9. INSTALL GENERATOR (See «REMOVAL & INSTALLATION» )
10. CHECK CRANKSHAFT PULLEY POSITION Check that the timing mark of the crankshaft pulley is aligned with timing mark "0" of the No. 1 timing belt cover.
11. INSTALL RH, LH CAMSHAFT TIMING PULLEYS Align the camshaft knock pin with the knock pin grove of the timing pulley, and side on the timing pulley. Using SST, install the pulley bolt. SST 09960-10010 (09962-01000, 09963-01000) Torque: 108 N.m (1,100 kgf.cm, 80 ft.lbf)
12. CONNECT TIMING BELT TO LH CAMSHAFT TIMING PULLEY Remove any oil or water on the LH camshaft timing pulley and clean it up. NOTE: Only wipe the pulleys; do not use any cleansing agent. Turn the LH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the LH camshaft timing pulley. Turn the LH camshaft timing pulley counterclockwise until there is tension between the crankshaft timing pulley and the LH camshaft timing pulley.
13. CONNECT TIMING BELT TO RH CAMSHAFT TIMING PULLEY Remove any oil or water on the RH camshaft timing pulley and water pump pulley, and clean them up. NOTE: Only wipe the pulleys; do not use any cleansing agent. Turn the RH camshaft timing pulley. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the RH camshaft timing pulley.
14. SET TIMING BELT TENSIONER Using a press, slowly press in the push rod using 981-9,807 N (100 - 1,000 kgf, 220 - 2,205 lbf) of pressure. Align the holes of the push rod and the housing, pass a 1.27 mm (0.050 in.) hexagon wrench through the holes to keep the setting position of the push rod. Release the press. Install the dust boot to the belt tensioner.
15. INSTALL TIMING BELT TENSIONER Temporarily install the belt tensioner with the 2 bolts. Alternately tighten the 2 bolts. Torque: 26 N.m (270 kgf.cm, 19 ft.lbf) Using pliers, remove the 1.27 mm (0.050 in.) hexagon wrench from the belt tensioner.
16. CHECK VALVE TIMING Temporarily install the crankshaft pulley bolt. Slowly turn the crankshaft pulley 2 revolutions from TDC to TDC. NOTE: Always turn the crankshaft pulley clockwise. Check that each pulley aligns with the timing marks (Scheme 60) If the timing marks do not align, remove the timing belt and reinstall it.
17. TIGHTEN CRANKSHAFT PULLEY BOLT Using SST, install the pulley bolt. SST 09213-70011 (90105-70020), 09330-00021 Torque: 245 N.m (2,500 kgf.cm, 181 ft.lbf)
18. INSTALL FAN BRACKET Install the fan bracket with the 2 bolts and the 2 nuts. Torque: 12 mm head 16 N.m (160 kgf.cm, 12 ft.lbf) 14 mm head 32 N.m (330 kgf.cm, 24 ft.lbf) HINT: Bolt Length: 106 mm (4.17 in.) for 12 mm head (A) 114 mm (4.49 in.) for 14 mm head (B)
19. INSTALL A/C COMPRESSOR (See «INSTALLATION» )
20. INSTALL NO. 2 TIMING BELT COVER Install the No. 2 timing belt cover with the 2 bolts. Torque: 16 N.m (160 kgf.cm, 12 ft.lbf)
21. INSTALL RH NO. 3 TIMING BELT COVER Fit the RH No. 3 timing belt cover, matching it with the fan bracket. Install the RH No. 3 timing belt cover with the 3 bolts and nut. Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf)
22. INSTALL LH NO. 3 TIMING BELT COVER Install the oil cooler pipe and the bolt. Run the camshaft position sensor wire through the LH No. 3 timing belt cover hole. Fit the LH No. 3 timing belt cover, matching it with the fan bracket. Install the LH No. 3 timing belt cover with the 4 bolts and the nut. Torque: 7.5 N.m (80 kgf.cm, 66 in.lbf) Install the wire grommet to the LH No. 3 timing belt cover. Install the sensor connector to the connector bracket. Connect the sensor connector. Install the sensor wire to the wire clamp on the LH No. 3 timing belt cover. Install the engine wire to the 2 wire clamps on the LH No. 3 timing belt cover.
23. INSTALL DRIVE BELT IDLER PULLEY Install the idler pulley and the cover plate with the bolt. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
24. INSTALL RADIATOR ASSEMBLY (See «INSTALLATION» )
25. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND DRIVE BELT Temporarily install the fan pulley, the fan, the fluid coupling assembly with the 4 nuts. Install the generator drive belt. (See «GENERATOR» ) Tighten the 4 nuts holding the fluid coupling to the fan bracket. Torque: 21 N.m (215 kgf.cm, 16 ft.lbf)
26. INSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY
27. INSTALL V-BANK COVER
28. FILL WITH ENGINE COOLANT
29. START ENGINE AND CHECK FOR LEAKS
30. RECHECK ENGINE COOLANT LEVEL
31. INSTALL BATTERY CLAMP COVER
32. INSTALL ENGINE UNDER COVER
33. INSTALL OIL PAN PROTECTOR

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

1. DRAIN ENGINE COOLANT
2. REMOVE V-BANK COVER Remove the V-bank covers.
3. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS (See «REMOVAL» )
4. REMOVE CAMSHAFT TIMING PULLEYS (See «REMOVAL» )
5. REMOVE CAMSHAFT POSITION SENSOR (See «REMOVAL» )
6. DISCONNECT PS PUMP FROM ENGINE (See «REMOVAL» )
7. REMOVE FRONT EXHAUST PIPE (See «COMPONENTS»(/lexus/lx/j100-2002-2007/remont/exhaust/#exhaust-system) )
8. REMOVE OIL DIPSTICK AND GUIDE FOR A/T
9. REMOVE IGNITION COILS (See «REMOVAL» )
10. REMOVE TIMING BELT REAR PLATES Remove the 3 bolts, the stud bolts, and the RH No. 1 timing belt rear plates. Disconnect the wire clamp from the LH timing belt rear plate. Remove the 3 bolts, the stud bolt, the LH No. 1 and the timing belt rear plates. NOTE: Be careful not to drop anything inside the timing belt cover. Do not allow the belt to contact correct with oil, water or dust.
11. DISCONNECT FUEL INLET HOSE (See «INSPECTION» )
12. REMOVE INTAKE MANIFOLD ASSEMBLY Disconnect the throttle control connector. Disconnect the VSV connector for EVAP. Disconnect the 8 injector connectors. Disconnect the ECT sensor connectors. Disconnect the water sender gauge connector. Disconnect the 8 ignition coil connectors. Disconnect the 2 oxygen sensor connectors. Disconnect the fuel pressure regulator vacuum hose from the fuel pressure regulator pipe. Disconnect the PCV hose from the PCV valve on the LR cylinder head. Disconnect the EVAP hose (from charcoal canister) from VSV for EVAP. Disconnect the EVAP hose (from charcoal canister) from the EVAP pipe on the intake manifold. Disconnect the EVAP hose (from intake air connector) from the EVAP pipe on the intake manifold. Disconnect the PS air hose from the intake manifold. Disconnect the No. 1 water bypass hose from the front water by-pass joint. Disconnect the 2 wire clamps from the wire clamp bracket on the RH delivery pipe. Remove the 2 bolts and disconnect the engine wire protector from the rear water bypass joint and the RH cylinder head. Remove the guide for A/T bracket from the LH cylinder head. Remove the 2 ground cables from the RH and LH cylinder head. Remove the 2 bolts and disconnect the engine wire protector from the intake manifold. Remove the engine wire from the engine hanger. Remove the engine wire from the wire bracket. Remove the RH rear and the LH front V-bank cover brackets. Remove the 6 bolts, the 4 nuts, the intake manifold assembly and the 2 gaskets.
13. DISASSEMBLE UPPER AND LOWER INTAKE MANIFOLDS Remove the throttle body (See «REMOVAL» ). Remove the 13 bolts, the 3 nuts, the upper intake manifold and the gasket. Disconnect the EVAP hose from the upper intake manifold, and remove the accelerator cable clamp and VSV for EVAP. Remove the bolt, the union, the 2 gaskets and the brake booster tube from the upper intake manifold. Remove the 2 bolts and the EVAP pipe from the intake manifold. Disconnect the fuel return hose from the fuel pressure regulator. Remove the 3 bolts holding the fuel return hose from the lower intake manifold. Remove the fuel pressure regulator, the fuel pressure pulsation damper and the 2 gaskets. Remove the bolt and rear fuel pipe. Remove the 2 delivery pipes and the 8 injectors (See «REMOVAL» ).
14. REMOVE WATER INLET AND INLET HOUSING ASSEMBLY (See «REMOVAL»(/lexus/lx/j100-2002-2007/remont/cooling-system-mechanical/#water-pump) )
15. REMOVE FRONT WATER BYPASS JOINT Remove the 4 nuts, the water bypass joint and the 2 gaskets.
16. REMOVE REAR WATER BYPASS JOINT Remove the 4 nuts, the water bypass joint and the 2 gaskets.
17. REMOVE ENGINE HANGERS
18. REMOVE OIL DIPSTICK AND GUIDE FOR A/T
19. REMOVE CYLINDER HEAD COVERS Remove the 18 bolts, the 18 seal washers, the cylinder head cover and gasket. Remove the 2 cylinder head covers.
20. IF NECESSARY, REMOVE SEMI-CIRCULAR PLUGS AND CAMSHAFT HOUSING PLUGS
21. REMOVE CAMSHAFTS NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. Otherwise, excessive pressure is put on the cylinder head journal thrust, causing a burr on the journal and damage on the camshaft. To avoid this, follow the steps below. Check the crankshaft pulley position. Check that the timing mark of the crankshaft pulley is in aligned with the centers of the crankshaft pulley bolt and idler pulley bolt. NOTE: Having the crankshaft pulley at the wrong angle can cause the piston head and the valve head to come into contact with each other when removing the camshaft, causing damage on them. So always set the crankshaft pulley at the correct angle. Remove the RH camshafts. Move a service bolt of the sub-gear upward by turning the hexagon shaped port of the exhaust camshaft with a wrench. Secure the sub-gear to the main gear with a service bolt. Recommended service bolt: HINT: When removing the camshafts, make sure that the torsional spring force of the sub-gear is eliminated by the above operation. Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10° angle by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. Uniformly loosen and remove the 22 bearing cap bolts a little at a time for several times in the sequence (Scheme 92) Remove the oil feed pipe, 9 bearing caps, cam shaft timing oil control valve and camshafts. Remove the LH camshafts. Move a service bolt of the sub-gear upward by turning the hexagon shaped port of the exhaust camshaft with a wrench. Secure the sub-gear to the main gear with a service bolt. Recommended service bolt: HINT: When removing the camshaft, make sure that the torsional spring force of the sub-gear is eliminated by the above operation. Align the timing mark (2 dot marks) of the camshaft drive gear by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. Evenly loosen and remove the 22 bearing cap bolts a little at a time for several times as in the sequence (Scheme 96) Remove the oil feed pipe, 9 bearing caps and camshafts. HINT: Arrange the bearing caps in correct order for installation.
22. DISASSEMBLE EXHAUST CAMSHAFTS Mount the hexagon wrench head portion of the camshaft in a vise. NOTE: Be careful not to damage the camshaft. Using SST, turn the sub-gear clockwise, and remove the service bolt. SST 09960-10010 (09962-01000, 09963-00500) Using snap ring pliers, remove the snap ring. Remove these parts: Wave washer Camshaft sub-gear Camshaft gear spring HINT: Arrange the camshaft sub-gears and gear spring (RH and LH sides). NOTE: Be careful not to damage the camshaft timing tube.
23. REMOVE OIL SEAL FROM INTAKE CAMSHAFT
24. REMOVE SPARK PLUGS
25. REMOVE CYLINDER HEAD AND EXHAUST MANIFOLD ASSEMBLIES Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in a little at a time for several times as in the sequence shown, then do the other side (Scheme 101) Remove the 20 cylinder head bolts and the plate washers. NOTE: Removing the bolts in incorrect order could cause a warp or cracks in the cylinder head. Do not drop the plate washer of the cylinder head bolt into A area in (Scheme 102). It will fall down to the oil pan through the cylinder head and the cylinder block. Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks. HINT: After lifting off the cylinder head, pry off the cylinder head and the cylinder block with a screwdriver. NOTE: Be careful not to damage the contact surfaces of the cylinder head and the cylinder block. The cylinder head should not be tilted so to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.
26. REMOVE RH EXHAUST MANIFOLD FROM CYLINDER HEAD Remove the 4 bolts and the heat insulator. Remove the 8 nuts, the exhaust manifold and the gasket.
27. REMOVE LH EXHAUST MANIFOLD FROM CYLINDER HEAD Remove the 4 bolts and the heat insulator. Remove the 8 nuts, the exhaust manifold and the gasket.

Scheme 100

Scheme 101

1. REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and the shims in correct order.
2. REMOVE VALVES Using SST, compress the valve spring and remove the 2 keepers. SST 09202-70020 Remove these parts: Spring retainer Valve spring Valve Spring seat HINT: Arrange the valves, the valve springs, the spring seats and the spring retainers incorrect order. Using needle-nose pliers, remove the oil seal.

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

1. CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface. Using a gasket scraper, remove all the gasket material from the cylinder block surface. Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high pressure compressed air.
2. REMOVE GASKET MATERIAL Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTE: Be careful not to scratch the cylinder block contact surface.
3. CLEAN COMBUSTION CHAMBERS Using a wire brush, remove all the carbon from the combustion chambers. NOTE: Be careful not to scratch the cylinder block contact surface.
4. CLEAN VALVE GUIDE BUSHINGS Using a valve guide bushing brush and solvent, clean all the guide bushings.
5. CLEAN CYLINDER HEAD Using a soft brush and solvent, thoroughly clean the cylinder head.
6. INSPECT FOR FLATNESS Using a precision straight edge and a feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warp. Maximum warpage: 0.10 mm (0.0039 in.) If the warp is greater than maximum, replace the cylinder head.
7. INSPECT FOR CRACKS Using a dye penetrate, check the combustion chamber, the intake ports, the exhaust ports and the cylinder head surface for cracks. If there is a crack, replace the cylinder head.
8. CLEAN VALVES Using a gasket scraper, chip off any carbon from the valve head. Using a wire brush, thoroughly clean the valve.
9. INSPECT VALVE STEMS AND GUIDE BUSHINGS Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 5.510 - 5.530 mm (0.2169 - 0.2177 in.) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intake 5.470 - 5.485 mm (0.2154 - 0.2159 in.) Exhaust 5.465 - 5.480 mm (0.2152 - 0.2157 in.) Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intake 0.025 - 0.060 mm (0.0010 - 0.0024 in.) Exhaust 0.030 - 0.065 mm (0.0012 - 0.0026 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than the maximum, replace the valve and the guide bushing. (See «REPLACEMENT» )
10. INSPECT AND GRIND VALVES Grind the valve enough to remove pits and carbon. Check that the valve is ground to the correct valve face angle. Valve face angle: 44.5° Check the valve head margin thickness. Standard margin thickness: IN 1.25 mm (0.049 in.) EX 1.40 mm (0.055 in.) Minimum margin thickness: 0.5 mm (0.020 in.) If the margin thickness is less than the minimum, replace the valve. Check the valve overall length. Standard overall length: Intake: 95.05 mm (3.7421 in.) Exhaust: 95.10 mm (3.7441 in.) Minimum overall length: Intake: 94.55 mm (3.7224 in.) Exhaust: 94.60 mm (3.7244 in.) If the overall length is less than the minimum, replace the valve. Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTE: Do not grind off to below the minimum.
11. INSPECT AND CLEAN VALVE SEATS Using a 45° carbide cutter, resurface the valve seats. Remove just enough metal to clean the seats. Check the valve seating position. Apply a light coat of Prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve. Check the valve face and seat for the following: If blue appears 360° around the face, the valve is concentric. If not, replace the valve. If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat. Check that the seat contact is in the middle of the valve face with the following width: 1.0 - 1.4 mm (0.039 - 0.055 in.) If not, correct the valve seats as follows: If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat. If the seating is too low on the valve face, use 60° and 45° cutters to correct the seat. Hand-lap the valve and valve seat with an abrasive compound. After hand-lapping, clean the valve and valve seat.
12. INSPECT VALVE SPRINGS Using a steel square, measure the deviation of the valve spring. Maximum deviation: 2.0 mm (0.079 in.) If the deviation is greater than the maximum, replace the valve spring. Using vernier calipers, measure the free length of the valve spring. Free length: 54.1 mm (2.130 in.) If the free length is not as specified replace the valve spring. Using a spring tester, measure the tension of the valve spring at the installed length. Installed tension: 204 - 226 N (20.8 - 23.0 kgf, 45.9 - 50.7 lbf) at 35.0 mm (1.378 in.) If the installed tension is not as specified, replace the valve spring.
13. INSPECT CAMSHAFT FOR RUNOUT Place the camshaft on V-blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.08 mm (0.0031 in.) If the circle runout is greater than the maximum, replace the camshaft.
14. INSPECT CAM LOBES Using a micrometer, measure the cam lobe height. Standard cam lobe height: Intake: 41.94 - 42.04 mm (1.6512 - 1.6551 in.) Exhaust: 41.96 - 42.06 mm (1.6520 - 1.6559 in.) Minimum cam lobe height: Intake: 41.79 mm (1.6453 in.) Exhaust: 41.81 mm (1.6464 in.) If the cam lobe height is less than the minimum, replace the camshaft.
15. INSPECT CAMSHAFT JOURNALS Using a micrometer, measure the journal diameter. Journal diameter: 26.954 - 26.970 mm (1.0612 - 1.0618 in.) If the journal diameter is not as specified, check the oil clearance.
16. INSPECT CAMSHAFT GEAR SPRING Using vernier calipers, measure the free distance between the spring ends. Free distance: 18.2 - 18.8 mm (0.712 - 0.740 in.) If the free distance is not as specified, replace the gear spring.
17. INSPECT CAMSHAFT BEARINGS Check that bearings for flaking and scoring. If the bearings are damaged, replace the bearing caps and cylinder head as a set.
18. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE Clean the bearing caps and the camshaft journals. Place the camshafts on the cylinder head. Lay a strip of plastigage across each of the camshaft journals. Install the bearing caps. (See «INSTALLATION» ) Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) NOTE: Do not turn the camshaft. Remove the bearing caps. Measure the Plastigage at its widest point. Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Completely remove the plastigage. Remove the camshafts.
19. INSPECT CAMSHAFT THRUST CLEARANCE Install the camshaft. (See «INSTALLATION» ) Using a dial indicator, measure the thrust clearance as moving the camshaft back and forth. Standard thrust clearance: Intake 0.040 - 0.090 mm (0.0016 - 0.0035 in.) Exhaust 0.040 - 0.085 mm (0.0016 - 0.0033 in.) Maximum thrust clearance: 0.12 mm (0.0047 in.) If the thrust clearance is greater than the maximum replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set. Remove the camshafts.
20. INSPECT CAMSHAFT GEAR BACKLASH Install the camshafts without installing the exhaust cam sub-gear and the front bearing cap. (See «INSTALLATION» ) Using a dial indicator, measure the backlash. Standard backlash: 0.020 - 0.200 mm (0.0008 - 0.0079 in.) Maximum backlash: 0.30 mm (0.0188 in.) If the backlash is greater than the maximum, replace the camshafts. Remove the camshafts.
21. INSPECT VALVE LIFTERS AND LIFTER BORES Using a caliper gauge, measure the lifter bore diameter of the cylinder head. Lifter bore diameter: 31.000 - 31.016 mm (1.2205 - 1.2211 in.) Using a micrometer, measure the lifter diameter at the valve lifter center line, 12.3 - 12.7 mm (0.484 - 0.500 in.) from the valve lifter head. Lifter diameter: 30.966 - 30.976 mm (1.2191 - 1.2195 in.) Subtract the lifter diameter from the lifter bore diameter. Standard oil clearance: 0.024 - 0.050 mm (0.0009 - 0.0020 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) If the oil clearance is greater than the maximum, replace the lifter. If necessary, replace the cylinder head.
22. INSPECT INTAKE MANIFOLD Upper intake manifold: Using a precision straight edge and a feeler gauge, measure the surface contacting of the lower intake manifold for a warp. Maximum warpage: 0.15 mm (0.0059 in.) If the warp is greater than the maximum, replace the upper intake manifold. Lower intake manifold: Using a precision straight edge and a feeler gauge, measure the surface contacting of the cylinder head and the upper intake manifold for a warpage. Maximum warpage: 0.15 mm (0.0059 in.) If the warp is greater than the maximum, replace the lower intake manifold.
23. INSPECT EXHAUST MANIFOLD Using a precision straight edge and a feeler gauge, measure the surface contacting of the cylinder head for a warp. Maximum warpage: 0.50 mm (0.0197 in.) If the warp is greater than the maximum, replace the manifold.
24. INSPECT CYLINDER HEAD BOLTS Using vernier calipers, measure the thread outside diameter of the bolt. Standard outside diameter: 9.810 - 9.960 mm (0.3862 - 0.3921 in.) Minimum outside diameter: 9.700 mm (0.3819 in.) If the diameter is less than the minimum, replace the bolt.

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

1. REPLACE VALVE GUIDE BUSHINGS Gradually heat the cylinder head to 80 - 100°C (176 - 212°F). Using SST and a hammer, tap out the guide bushing. SST 09201-10000 (09201-01060), 09950-70010 (09951-07100) Using a caliper gauge, measure the bushing bore diameter of the cylinder head. Select a new guide bushing (STD or O/S 0.05). If the bushing bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bushing bore to the following dimension: 10.335 - 10.356 mm (0.4069 - 0.4077 in.) If the bushing bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head. HINT: The intake bushing and the exhaust bushing differ in their sizes. Gradually heat the cylinder head to 80 - 100°C (176 - 212°F). Using SST and a hammer, tap in a new guide bushing to the specified protrusion height. Protrusion height: Intake 9.2 - 9.8 mm (0.362 - 0.386 in.) Exhaust 8.2 - 8.8 mm (0.323 - 0.346 in.) SST 09201 - 10000 (09201-01060), 09950-70010 (09951-07100) Using a sharp 5.5 mm reamer, ream the guide bushing to obtain the standard specified clearance (See «INSPECTION» ) between the guide bushing and the valve stem.
2. REPLACE SPARK PLUG TUBE GASKETS Bend the 4 ventilation case claws installed on the cylinder head cover to an angle of 90° or more. Using a screwdriver, pry out the gasket. NOTE: Be careful not to damage the cylinder head cover. Tape up the screwdriver tip. Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover. SST 09950-60010 (09551-00240, 09951-00440, 09952-06010), 09950-70010 (09951-07100) NOTE: Be careful of the installation direction. Apply a light coat of MP grease to the gasket lip. Put the 4 ventilation case claws back to its original position.

See also:
• COMPONENTS
• REMOVAL