Engine Controls - Remove/install/overhaul: Removal & Installation Lexus LX J80

Removal & Installation

Ensure ignition is off. Remove ECM. See ECM LOCATION table. To install, reverse removal procedure.

ECM LOCATION

1. Ensure ignition is off. Disconnect electrical connector at airflow meter. Airflow meter is located between air cleaner hose to throttle body and air cleaner assembly.
2. Remove air intake hose(s) as necessary. Remove airflow meter mounting bolt(s)/nut(s). Remove airflow meter and gasket (if equipped). To install, reverse removal procedure using NEW gasket (if equipped).

1. Ensure ignition is off. Disconnect electrical connector from ECT sensor. See «ENGINE COOLANT TEMPERATURE (ECT) SENSOR LOCATION»(ref-22151-S21718387142001010300000) table. To verify wire colors for proper sensor identification, see appropriate wiring diagram in «WIRING DIAGRAMS»(ref-22132) article. NOTE: The ECT sensor may be also identified using appropriate illustration in «THEORY/OPERATION»(ref-21908) article.
2. Drain cooling system. Remove ECT sensor and gasket. To install, reverse removal procedure using NEW gasket. Tighten ECT sensor to specification (if available). See «TORQUE SPECIFICATIONS»(ref-22151-S04812748572001010300000) table. Refill cooling system.

ENGINE COOLANT TEMPERATURE (ECT) SENSOR LOCATION

1. Disconnect electrical connector at EGR gas temperature sensor. See «EGR GAS TEMPERATURE SENSOR LOCATIONS»(ref-22151-S42345911182001010300000) table. The EGR gas temperature sensor contains a Dark Gray 2-pin electrical connector. NOTE: The EGR gas temperature sensor may be also identified using appropriate illustration in «THEORY/OPERATION»(ref-21908) article.
2. Remove EGR gas temperature sensor. To install, reverse removal procedure. Tighten EGR temperature sensor to specification (if available). See «TORQUE SPECIFICATIONS»(ref-22151-S04812748572001010300000) table.

EGR GAS TEMPERATURE SENSOR LOCATIONS

1. Disconnect electrical connector at knock sensor. Knock sensors are located on side of cylinder block, just below the cylinder head and intake manifold. (Scheme 1) Knock sensor No. 1 is at the front of cylinder block and knock sensor No. 2 is at the rear of cylinder block. Remove knock sensor from cylinder block.
2. Using ohmmeter, check that no continuity exists between electrical terminal of knock sensor and body of knock sensor. Replace knock sensor if continuity exists.
3. To install, reverse removal procedure. Tighten knock sensor to specification. See «TORQUE SPECIFICATIONS»(ref-22151-S04812748572001010300000) table.

Scheme 1

Removal (A/T Models)

1. The PNP switch is located on side of transmission/transaxle. (Scheme 2) Remove necessary components for access to PNP switch.
2. Disconnect electrical connector from PNP switch. Disconnect shift cable or shift linkage from control lever (if equipped) on transmission/transaxle for access to PNP switch.
3. Remove nut, washer and control lever (if equipped) from transmission/transaxle. Bend tabs upward on lock plate, away from PNP switch retaining nut. Remove PNP switch retaining nut, lock plate, PNP switch retaining bolt(s) and PNP switch.

Installation (A/T Models)

1. Using NEW lock plate, install PNP on transaxle. Install and tighten PNP switch retaining nut and PNP switch retaining bolt(s) to specification. See «TORQUE SPECIFICATIONS»(ref-22151-S04812748572001010300000) table. Bend over tab on lock plate against PNP switching retaining nut.
2. Reinstall control lever, washer and nut on PNP switch. Reconnect shift cable or shift linkage on control lever. Check that engine starts only with shift lever in Park and Neutral. If PNP switch adjustment is required, go to next step.
3. Ensure parking brake is applied. Place shift lever in Neutral. It may be necessary to remove control lever (if equipped) for access to PNP switch retaining bolt(s). Loosen PNP switch retaining bolt(s).
4. Rotate PNP switch so neutral base line aligns with the groove. (Scheme 3) Tighten PNP switch retaining bolt(s) to specification. See «TORQUE SPECIFICATIONS»(ref-22151-S04812748572001010300000) table.
5. Ensure continuity exists between specified terminals on PNP in relation to shift lever position. See steps described in «SYSTEM/COMPONENT TESTS»(ref-21992) article. Reinstall electrical connector.

Scheme 2

Scheme 3

The TP sensor is mounted on throttle body. Service information is not available from manufacturer. For adjustment of TP sensor, see ADJUSTMENTS article.

Vehicle speed sensor is the rear speed sensor on driver's side of transmission, near transfer case, and contains Black 3-pin electrical connector. Service information is not available from manufacturer.

Removal

1. Disconnect electrical connector at distributor. Remove distributor cap and gasket from distributor.
2. Rotate crankshaft pulley until groove on crankshaft pulley aligns with "0" mark on timing chain cover to position cylinder No. 1 (front cylinder) at TDC on compression stroke. Ensure rotor is in proper position. (Scheme 4) If rotor is not in proper position, rotate crankshaft pulley clockwise one full revolution.
3. Remove distributor hold-down bolt and distributor. Remove "O" ring from distributor housing.

Only rotor is serviceable. Remove rotor from distributor. To check pick-up coils, see PICK-UP COIL RESISTANCE and PICK-UP COIL AIR GAP under IGNITION CHECKS in BASIC TESTING article. Pick-up coils and distributor must be replaced as an assembly if defective.

Installation

1. Ensure cylinder No. 1 (front cylinder) is at TDC on compression stroke and groove on crankshaft pulley aligns with "0" mark on timing chain cover. It may be necessary to remove valve cover and check that the one-dot and 2-dot timing marks on camshaft sprockets are aligned. (Scheme 5) If timing marks are not aligned, rotate crankshaft pulley one full revolution.
2. Install NEW "O" ring on distributor housing. Coat "O" ring with engine oil. Align protrusion on drive gear with groove on distributor housing. (Scheme 6)
3. Install distributor, aligning center of distributor mounting flange bolt hole with bolt hole on cylinder head. Install and tighten distributor hold-down bolt to specification. See «TORQUE SPECIFICATIONS»(ref-22151-S04812748572001010300000) table.
4. To install remaining components, reverse removal procedure. Check ignition timing. See «ADJUSTMENTS»(ref-21890) article.

Scheme 4

Scheme 5

Scheme 6

1. Crankshaft position sensor is located on front of engine, just in front of the oil pan, below the crankshaft pulley. Disconnect electrical connector for crankshaft position sensor. (Scheme 7)
2. Remove lower engine cover. Crankshaft position sensor protector is located below wiring harness and crankshaft position sensor. Remove crankshaft position sensor protector for access to crankshaft position sensor and wiring harness.
3. Disconnect electrical connector for crankshaft position sensor. Remove crankshaft position sensor.
4. To install, reverse removal procedure. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-22151-S04812748572001010300000) table.

Scheme 7

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-22151-S37712024782001010300000) . Remove fuel tank filler cap to release any fuel pressure from fuel tank.
2. Remove second seat, scuff plate, step plate, floor mats and cover plate on floor panel for access to fuel pump. Disconnect electrical connector at fuel pump.
3. Remove union bolt and disconnect fuel outlet line from fuel pump mounting bracket. Disconnect fuel return hose from fuel pump mounting bracket.
4. Remove fuel pump mounting bracket-to-fuel tank bolts. Remove fuel pump assembly and gasket from fuel tank. Use care not to damage fuel filter on bottom of fuel pump and fuel gauge sending unit when removing fuel pump.

1. To install, reverse removal procedure using NEW gaskets on fuel pump mounting bracket and fuel outlet line union bolt. Tighten fuel pump mounting bracket-to-fuel tank bolts and fuel outlet line union bolt to specification. See «TORQUE SPECIFICATIONS»(ref-22151-S04812748572001010300000) table.
2. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION in «BASIC TESTING»(ref-21926) article.

1. Fuel pressure control VSV is located at lower front corner of air intake chamber, near the dipstick and contains a Brown 2-Pin electrical connector. NOTE: Fuel pressure control VSV may be also identified using appropriate illustration in «THEORY/OPERATION»(ref-21908) article.
2. Air intake chamber must be removed for access to fuel pressure control VSV. (Scheme 8) Drain cooling system. Disconnect control cables, electrical connectors, vacuum hoses and air cleaner hose at throttle body.
3. Remove EGR valve and EGR vacuum modulator. Remove power steering reservoir from air intake chamber. Disconnect necessary electrical connectors, ground straps, vacuum hoses, air hoses and coolant hoses for removal of air intake chamber. Remove dipstick.
4. Remove air intake chamber support brace. (Scheme 8) Remove air intake chamber and gaskets. Disconnect electrical connector and vacuum hoses from fuel pressure control VSV. Remove fuel pressure control VSV.
5. To install, reverse removal procedure. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-22151-S04812748572001010300000) table.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-22151-S37712024782001010300000) . Disconnect vacuum hose and fuel return hose from fuel pressure regulator, located on end of fuel rail.
2. Loosen fuel pressure regulator lock nut and unscrew fuel pressure regulator with "O" ring from fuel rail. Remove "O" ring from fuel pressure regulator.

1. To install, ensure lock nut is fully screwed onto fuel pressure regulator. Install NEW "O" ring on fuel pressure regulator. Coat "O" ring with gasoline.
2. Screw fuel pressure regulator fully into fuel rail. Rotate fuel pressure regulator counterclockwise until hose fittings aligned with fuel rail and pointing inward toward center of fuel rail. Tighten fuel pressure regulator lock nut to specification. See «TORQUE SPECIFICATIONS»(ref-22151-S04812748572001010300000) table.
3. Reconnect vacuum hose and fuel return hose. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION in «BASIC TESTING»(ref-21926) article.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(ref-22151-S37712024782001010300000) under FUEL SYSTEM. Drain cooling system. Disconnect control cables, electrical connectors and vacuum hoses at throttle body.
2. Remove EGR and EGR vacuum modulator. Remove power steering reservoir from air intake chamber. Disconnect necessary electrical connectors, ground straps, vacuum hoses, air hoses and coolant hoses for removal of air intake chamber. (Scheme 8) Remove dipstick.
3. Remove air intake chamber support brace. (Scheme 8) Remove air intake chamber and gaskets. Disconnect vacuum hose and fuel return hose from fuel pressure regulator. Remove fuel return pipe.
4. Remove union bolts and gaskets from fuel inlet pipe, located between fuel filter and fuel rail. Remove fuel inlet pipe. Note location of electrical connectors on fuel injectors for reassembly reference. Disconnect electrical connectors at fuel injectors. CAUTION: When removing fuel rail, use care not to allow fuel injectors to fall from fuel rail.
5. Remove fuel rail-to-intake manifold bolts. Remove fuel rail with fuel injectors. Remove spacers and insulators from intake manifold. Remove fuel injectors from fuel rail. Remove "O" ring and grommet from fuel injector.

1. To install, reverse removal procedure using NEW grommets, "O" rings, insulators and gaskets. Coat "O" ring with gasoline before installing "O" ring on fuel injector. Use twisting motion when installing fuel injector on fuel rail. Ensure insulators and spacers are installed on intake manifold.
2. When installing fuel rail, install fuel rail with fuel injectors on intake manifold. Loosely install fuel rail-to-intake manifold bolts.
3. Ensure fuel injectors rotate smoothly. If fuel injectors do not rotate smoothly, check for improper "O" ring installation. Ensure electrical connector on each fuel injector is facing upward.
4. Tighten fuel rail-to-intake manifold bolts to specification. See «TORQUE SPECIFICATIONS»(ref-22151-S04812748572001010300000) table. To install remaining components, reverse removal procedure. Tighten bolts/nuts to specification. Fill cooling system.
5. Operate fuel pump and check for fuel leaks. See FUEL PUMP OPERATION in «BASIC TESTING»(ref-21926) article.

Scheme 8

1. Drain cooling system. Remove air cleaner hose from throttle body. Disconnect control cables, air hoses, vacuum hoses and electrical connectors at throttle body.
2. Remove bolts, throttle body and gasket. Remove Idle Air Control (IAC) valve and "O" ring from throttle body (if necessary).

To install, reverse removal procedure using NEW gasket and "O" ring. Tighten bolts to specification. See TORQUE SPECIFICATIONS table. Fill cooling system.

IAC valve is located on throttle body. See THROTTLE BODY under FUEL SYSTEM for servicing of IAC valve.

1. The EGR VSV is located at lower rear corner of air intake chamber and contains a Blue 2-Pin electrical connector. NOTE: EGR VSV may be also identified using appropriate illustration in «THEORY/OPERATION»(ref-21908) article.
2. Air intake chamber must be removed for access to EGR VSV. (Scheme 8) Drain cooling system. Disconnect control cables, electrical connectors, vacuum hoses and air cleaner hose at throttle body.
3. Remove EGR valve and EGR vacuum modulator. Remove power steering reservoir from air intake chamber. Disconnect necessary electrical connectors, ground straps, vacuum hoses, air hoses and coolant hoses for removal of air intake chamber. Remove dipstick.
4. Remove air intake chamber support brace. (Scheme 8) Remove air intake chamber and gaskets. Disconnect electrical connector and vacuum hoses from EGR VSV. Remove EGR VSV.
5. To install, reverse removal procedure. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-22151-S04812748572001010300000) table.

For EGR valve servicing, procedure is just primarily an unbolt and bolt-on procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS table.