3.0L V6: Removal & Installation Lexus RX I

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 (ES300)

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-4442-S22239184532000062700000) . Drain cooling system and engine oil. Remove hood. Remove battery and battery tray. Remove engine fender apron seals. Using 5-mm hexagon wrench, remove 3 cap nuts and remove "V" bank cover.
2. Disconnect accelerator cable. Remove air cleaner cap assembly and air cleaner case. Remove cruise control actuator and bracket. Remove radiator and coolant reservoir tank.
3. Remove front exhaust pipe-to-center exhaust pipe nuts. Remove front exhaust pipe-to-exhaust manifold nuts. Remove front exhaust pipe.
4. Disconnect electrical connections at ignitor and noise filter near left strut tower. Disconnect necessary coolant hoses, electrical connections, fuel lines and vacuum hoses.
5. Remove lower panel on passenger side of instrument panel. Disconnect 3 ECM connectors. Disconnect 3 engine wire connectors from ECM bracket. Disconnect grommet from cowl panel and pull engine wire harness out through firewall.
6. Remove front wheels. Remove left axle shaft lock nut. Drain transmission fluid. Disconnect tie rod end from steering knuckle. Disconnect lower ball joint from lower suspension arm. Tap axle shaft with plastic hammer to disconnect axle shaft from axle hub. Pull axle shaft outward, and separate from axle hub. Remove snap ring and remove left axle shaft. Remove right axle shaft lock nut. Remove snap ring and remove right axle shaft.
7. Disconnect A/C compressor with hoses attached and secure aside. Disconnect transmission control cable from transaxle. Disconnect power steering pump with hoses attached and secure aside.Disconnect left mounting insulator-to-transaxle bolts. Disconnect rear rear engine mounting bracket from front frame. Remove 4 bolts and engine mounting absorber. Remove front engine mounting insulator-to-front frame bolts. Attach engine sling to engine hangers. CAUTION: DO NOT attempt to hang engine by hooking chain to any other part.
8. Remove 4 bolts, engine control rod and right mounting bracket. Remove engine and transaxle from vehicle. DO NOT hit Park Neutral Position (PNP) switch. Ensure engine is clear of all wiring, hoses and cables. Place engine and transaxle assembly onto stand. Remove front and rear mounting insulators and bracket assemblies from engine. Separate engine and transaxle.

Scheme 15

1. Assemble engine and transaxle. Install rear and front mounting insulators. Attach engine sling to engine hangers. Tilt transaxle downward, and lower engine into engine compartment. Align right and left mountings with body bracket to ensure engine is level.
2. Temporarily install No. 2 right engine mounting bracket and engine moving control rod with 3 bolts. Tighten bolts "A", "B", "C" and "D". (Scheme 15) Install mounting insulator with 3 bolts.
3. Install engine mounting absorber with 4 bolts. Connect rear and left engine mounting insulators. Remove engine sling. Connect transaxle control cable to transaxle. Install power steering pump and 2 bolts. Install drive belt. Connect power steering pressure tube with 2 nuts.
4. Install A/C compressor and drive belt adjusting bar bracket. Tighten nuts and bolt to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000). Install drive belt. Connect A/C compressor connector. Install axle shafts in reverse order of removal.
5. Push engine wire through cowl panel. Install grommet. Connect 3 engine ECM connectors. Connect 3 cowl wire connectors to connectors on bracket. Install lower instrument panel. Connect connectors, cable clamps and hoses.
6. Temporarily install 3 new gaskets and front exhaust pipe. Install 2 bolts, 2 compression rings and 4 nuts. Tighten 4 nuts holding exhaust manifolds to front exhaust pipe. Tighten 2 bolts and 2 compression rings holding front exhaust pipe to center exhaust pipe. Install support stay with 2 bolts.
7. Install radiator, cruise control actuator and air cleaner cap assembly. Connect accelerator cable. Using 5-mm hexagon wrench, install "V" bank cover with 3 nuts. Press down "V" bank cover fastener.
8. Install engine fender apron seals. Install battery tray and battery. Install hood, and fill engine with oil and coolant. Check for leaks.

Scheme 16

Scheme 17

1. Remove engine undercover. Drain coolant and engine oil. Remove hood. Remove outer cowl top panel assembly. Remove battery and battery tray. Using 5-mm hexagon wrench, remove 3 cap nuts and remove "V" bank cover. Disconnect necessary clamps and hoses, and remove air cleaner cap and case assembly.
2. Disconnect accelerator cable from throttle body. Remove cruise control actuator. Disconnect master cylinder and set aside. Disconnect engine wire from upper suspension brace. Disconnect 2 heater hoses. Remove 4 nuts and remove upper front suspension brace. Disconnect generator wire. Remove ground connections from fender aprons. Disconnect junction block connectors.
3. Disconnect brake booster vacuum hose, heater hoses and fuel inlet hose. Remove necessary vacuum hoses. Remove upper and lower radiator hoses. Disconnect 2 transmission cooler lines from transmission. Remove passenger side instrument panel lower cover. Remove glove box. Disconnect ECM connectors. Remove nuts retaining engine wire to cowl panel, and pull out engine wire harness.
4. Remove generator. Disconnect A/C compressor and set aside. Disconnect transmission shift control cable from transaxle. Remove 2 nuts from No. 2 front exhaust pipe-to-catalytic converter. Remove 2 nuts retaining No. 2 exhaust pipe-to-exhaust pipe. Remove No. 2 exhaust pipe. Remove front exhaust pipe. (Scheme 16) Remove right-side fender apron seal.
5. Disconnect stabilizer bar links. On 2WD models, remove front wheels. Remove left ABS speed sensor. Remove left axle shaft lock nut. Drain transmission fluid. Disconnect tie rod end from steering knuckle. Disconnect lower ball joint from lower suspension arm. Place mating marks on axle shaft inboard joint-to-outboard joint shafts. With brakes applied, remove 6 hex bolts from joint. Tap axle shaft with plastic hammer to disconnect axle shaft from axle hub. Pull axle shaft outward, and separate from transmission. Remove right axle shaft lock nut. Remove snap ring and remove right axle shaft.
6. On 4WD models, remove 4 nuts, bolts and washers and remove front drive shaft. On all models, remove lower bolt and disconnect steering column intermediate shaft. Disconnect vacuum hoses from front frame. Disconnect power steering hose from reservoir. Disconnect transmission oil cooler pipe from front frame. Disconnect front fender apron liners. Attach engine sling to engine. Remove engine moving control rod and No. 2 engine mounting bracket.
7. Remove 8 bolts and 4 lower engine braces. Lower engine, transmission and front frame assembly from vehicle. Remove power steering pressure switch connector. Disconnect power steering pressure tube. Remove drive belt. Remove power steering pump. On 4WD models, remove front stabilizer and power steering gear assembly. (Scheme 17) On all models, remove front frame assembly. Remove engine mounting absorber. Remove transmission-to-left engine mounting insulator bolts. Remove rear engine mounting insulator nut, and remove front frame assembly.
8. Remove front engine mounting insulator. Remove rear engine mounting bracket. Separate engine from transaxle.

Scheme 18

Scheme 19

1. Install engine to transmission. Install rear engine mounting bracket with 4 bolts. Install front mounting insulator with 4 bolts. Install rear engine mounting bracket nut. Install left engine mounting insulator with 4 bolts. Install engine mounting absorber with 3 bolts. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000).
2. On 4WD models, install power steering gear and front stabilizer. On all models, install power steering pump. Install drive belt. Connect power steering pressure tube and oil pressure switch connector. Install engine sling. Raise engine and transmission into vehicle. Install 4 lower braces with 8 bolts. (Scheme 18) Tighten bolts "A" and "B" to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000).
3. Temporarily install No. 2 right engine mounting bracket and engine moving control rod with 8 bolts. (Scheme 19) Tighten bolts "A", "B", "C" and "D" to specifications. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000). Remove engine sling. Connect fender liners. Connect transmission oil cooler pipe. Connect power steering hose to reservoir. Connect vacuum hoses to front frame. Connect steering intermediate shaft. To install, axle shafts, reverse removal procedure. On 4WD, connect stabilizer bar links and install drive shaft.
4. To complete installation, reverse removal procedure. Tighten all nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000). Refill transmission fluid, engine oil and coolant. Check for leaks.

Removal

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-4442-S22239184532000062700000). Drain cooling system. On RX300, remove outer cowl top panel. On all models, remove right fender apron seal. Remove generator drive belt. Remove power steering pump. Remove front exhaust pipe.
2. Using 5-mm hexagon wrench remove 3 cap nuts from "V" bank cover and remove "V" bank cover. Remove air cleaner cap and airflow meter with air cleaner hose. Remove cruise control actuator and bracket. Disconnect necessary electrical connections, ground straps, coolant hoses, fuel lines and vacuum hoses for removal of air intake chamber. Remove 2 bolts and No. 1 engine hangar.
3. Remove nuts and air intake chamber located above intake manifold. (Scheme 20) Disconnect fuel injector connectors. Disconnect fuel inlet hose from fuel filter. Disconnect heater hose from intake manifold. Remove bolts, nuts and washer from intake mainfold and remove intake mainfold, fuel pipes and fuel injectors as an assembly. CAUTION: DO NOT allow injectors to fall from delivery pipe when removing from intake manifold.
4. Disconnect Engine Cooling Temperature (ECT) sensor and sending unit. Disconnect ground strap connector. Disconnect upper radiator hose. Disconnect engine coolant reservoir hose. Remove bolts, nuts and plate washers. Disconnect water by-pass hose, and remove thermostat housing. Remove 2 gaskets.
5. Remove ignition coils and spark plugs. Mark ignition coil location for reassembly reference. Remove timing belt, camshaft sprockets and No. 2 idler pulley. See «TIMING BELT»(ref-4442-S41089217502000062700000). Disconnect 3 engine wire clamps from timing belt cover. Remove 6 bolts and No. 3 timing belt cover.
6. Remove camshaft position sensors. Remove camshaft timing oil control valves. Remove nut, and disconnect engine wire protector from right cylinder head. Disconnect engine wire protector from left cylinder head. Remove 2 bolts and remove rear plate from left cylinder head. Disconnect water inlet pipes from left cylinder head. Remove "O" ring from inlet pipe.
7. Remove power steering pump bracket from front of cylinder head. Disconnect airflow sensor connector, remove bolt and nut and remove right exhaust manifold stay. Remove 6 nuts, right exhaust manifold and gasket. Repeat procedure for left exhaust manifold.
8. Remove bolt holding oil dipstick guide to left cylinder head. Pull out dipstick guide with dipstick from No. 1 oil pan. Remove "O" ring from dipstick guide. Remove 9 bolts, cylinder head cover and gasket. (Scheme 21) Remove 2 cylinder head covers. Remove camshafts. See «CAMSHAFT»(ref-4442-S30780122482000062700000).
9. Using 8-mm hexagon wrench, remove recessed cylinder head bolts (one on each cylinder head). (Scheme 22) Loosen 12-point cylinder head bolts in sequence using several steps. (Scheme 22) Remove 12-point cylinder head bolts, cylinder head and cylinder head gasket.

Scheme 20

Scheme 21

Scheme 22

Removal & Installation (Oil Pump Installed)

1. Remove timing belt and crankshaft sprocket. See «TIMING BELT»(ref-4442-S41089217502000062700000) . Using a knife, cut off oil seal lip. Pry oil seal from oil pump body. DO NOT damage sealing surfaces.
2. To install, apply grease to lip of new oil seal. Using hammer and Oil Seal Installer (SST 09223-00010), install oil seal until surface is even with oil pump body. To install remaining components, reverse removal procedure.

Removal & Installation (Oil Pump Removed)

Pry oil seal from oil pump body. To install, use hammer and Oil Seal Installer (SST 09223-00010). Install oil seal until surface is even with oil pump body. Apply grease to seal lip of oil seal.

Scheme 23

1. Disconnect negative battery cable. On RX300, remove outer cowl top panel. On all models, remove front upper suspension brace from inside engine compartment. Disconnect coolant reservoir hose from water outlet. Raise and support vehicle. Remove passenger-side front wheel. Remove right fender apron seal. Remove accessory drive belts.
2. Disconnect ground strap connectors. Remove engine stabilizer rod, engine right mounting bracket. Remove generator bracket for access to timing belt covers.
3. Hold crankshaft pulley, and remove crankshaft pulley bolt. Using puller, remove crankshaft pulley.
4. Remove No. 1 (lower) timing belt cover. Remove timing belt guide. Remove No. 2 (upper) timing belt cover and gasket. (Scheme 23) Remove right engine mounting bracket.
5. Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. (Scheme 24)
6. Ensure timing marks on camshaft sprockets are aligned with timing mark on No. 3 timing belt cover. (Scheme 24) If timing marks are not aligned, rotate crankshaft clockwise one full revolution (360 degrees). Remove crankshaft pulley bolt from crankshaft. CAUTION: If reusing timing belt, ensure 3 reference marks and front mark are on timing belt. (Scheme 25) If marks are not apparent, place reference mark on timing belt at timing mark area on camshaft sprockets or dot area on crankshaft sprocket for reassembly reference. Place front mark on timing belt to indicate direction of timing belt installation.
7. Alternately loosen 2 bolts and remove timing belt tensioner and dust boot. (Scheme 23) Remove timing belt.
8. If removing camshaft timing sprockets, use Camshaft Sprocket Wrench (09960-10010) to hold camshaft sprocket. Using Adapter (09249-63010), remove sprocket bolt and remove camshaft sprockets.
9. If required, remove No. 1 and 2 belt idler pulleys. (Scheme 23) Remove timing belt plate near crankshaft sprocket. Using puller, remove crankshaft sprocket.

Scheme 24

Scheme 25

Installation

1. Align crankshaft pulley set key with key groove of timing pulley and slide on timing pulley. Install crankshaft sprocket with sensor side inward.
2. Install timing belt plate. Install and tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000). Install No. 1 and 2 idler pulleys (if removed). Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000). Ensure idler pulleys are clean and rotate smoothly.
3. If installing camshaft sprockets, ensure camshaft sprockets are installed with flange in correct direction. Install right camshaft sprocket with flange outward (away from cylinder head). Install left camshaft sprocket with flange inward (against cylinder head).
4. Align hole in camshaft sprocket with pin in camshaft, and install sprocket. Install and tighten camshaft sprocket bolt to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000).
5. Temporarily install crankshaft pulley bolt in crankshaft. Using crankshaft pulley bolt, rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. (Scheme 24)
6. Using camshaft sprocket holder, rotate each camshaft sprocket so timing mark on camshaft sprocket aligns with timing mark on No. 3 timing belt cover. (Scheme 25)
7. Align reference marks on timing belt with dot on crankshaft sprocket and timing marks on camshaft sprocket. Ensure front mark is pointing toward timing belt end of engine.
8. Install timing belt on crankshaft sprocket, water pump pulley, left camshaft sprocket, No. 2 idler pulley, right camshaft sprocket and No. 1 idler pulley. Using press, apply pressure on rod of timing belt tensioner until rod is retracted and holes in rod and housing are aligned. (Scheme 26)
9. Install hexagon wrench through holes in housing and rod to hold rod in retracted position. (Scheme 26) Release press, and install dust boot on timing belt tensioner. Install timing belt tensioner. Install and alternately tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000).
10. Remove hexagon wrench from timing belt tensioner. Rotate crankshaft clockwise until timing mark on crankshaft sprocket aligns with timing mark on oil pump body. (Scheme 24)
11. Ensure timing mark on each camshaft sprocket is aligned with timing mark on No. 3 timing belt cover. (Scheme 25) If all timing marks are not aligned, remove and reinstall timing belt. Remove crankshaft pulley bolt.
12. Using NEW gaskets, install No. 1 and 2 timing belt covers. Install engine wire protector clamps to No. 3 timing belt cover. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000).
13. Align and install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000).
14. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000).

Scheme 26

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

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

Remove transaxle and drive plate. See TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Using a knife, cut off oil seal lip. Pry oil seal from crankshaft rear oil seal housing. DO NOT damage sealing surfaces.

1. Ensure all sealing surfaces are clean. Apply grease to lip of new oil seal. Using Oil Seal Installer (SST 09223-15030), install oil seal in crankshaft rear oil seal housing until oil seal is even with housing surface.
2. Apply Loctite to drive plate bolts. Install and tighten drive plate bolts to specification in a crisscross pattern. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000) . To install remaining components, reverse removal procedure.

1. Disconnect negative battery cable. Drain cooling system. Remove timing belt, camshaft sprockets and No. 2 idler pulley. See «TIMING BELT»(ref-4442-S41089217502000062700000) .
2. Remove No. 3 (rear) timing belt cover. Remove bolts, nuts, water pump and gasket.

To install, reverse removal procedure using NEW gaskets. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS . Ensure proper procedure is followed when installing timing belt. Fill cooling system.

Scheme 27

1. Disconnect negative battery cable. On RX300, remove outer cowl top panel. Remove front upper suspension brace inside engine compartment. On all models, raise and support vehicle. Drain engine oil. Remove right front wheel and fender apron seal. Remove generator and A/C compressor from engine. Remove power steering drive belt and adjusting strut. Remove front exhaust pipe from between exhaust manifolds and catalytic converter. On RX300, remove catalytic converter.
2. On ES300, remove oil level sensor from lower corner of engine block. On all models, remove timing belt. See «TIMING BELT»(ref-4442-S41089217502000062700000). Remove timing pulleys and No. 3 timing belt cover. Remove A/C compressor and housing bracket.
3. Remove No. 2 oil pan bolts and nuts. Install Seal Cutter (SST 09032-00100) between No. 1 and 2 oil pans. Carefully tap seal cutter around No. 2 oil pan to loosen seal. DO NOT damage sealing surfaces. Remove No. 2 oil pan.
4. Remove oil strainer and gasket. (Scheme 27) Remove 2 bolts and flywheel housing undercover located at rear of No. 1 oil pan. Remove exhaust pipe stay, if equipped. Remove 19 bolts. Using screwdriver, remove oil pan by prying portions between cylinder block and oil pan. Remove No. 1 oil pan. NOTE: DO NOT damage contact surfaces of cylinder block and oil pan.
5. Remove baffle plate from No. 1 oil pan. Remove crankshaft position sensor. (Scheme 27)

Scheme 28

1. Install crankshaft position sensor. Install baffle plate on No. 1 oil pan (if necessary). Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000).
2. Ensure sealing surfaces are clean. Apply Seal Packing (08826-00080) or equivalent to No. 1 oil pan. (Scheme 28) Install oil pan and tighten bolts to specifications. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000).
3. Install flywheel housing undercover and exhaust pipe support stay, if equipped. Install oil strainer.
4. Apply seal packing to No. 2 oil pan. (Scheme 28) Ensure seal width is 3.0-4.0 mm. Install No. 2 oil pan with 19 bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000).
5. Install NEW gasket to oil level sensor. Install oil level sensor. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000). To install remaining components, reverse removal procedure.

Removal & Disassembly

Remove No. 1 and 2 oil pans. See OIL PAN under REMOVAL & INSTALLATION. Remove 9 bolts, oil pump and "O" ring. Remove oil pump body cover and oil pump components. (Scheme 29)

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure both rotors are installed in oil pump body with identification mark (triangle mark) facing oil pump body cover. Install oil pump body cover.
2. Using NEW gasket, install and tighten relief valve plug to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000) . Using Oil Seal Installer (SST 09223-00010), install crankshaft front seal (if removed) until surface is even with oil pump body. Coat seal lip with grease.
3. To install, apply sealant on rear of oil pump. Install NEW "O" ring on cylinder block. Install oil pump. Ensure splined teeth on drive rotor of oil pump engages with splines on crankshaft.
4. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-4442-S26673951792000062700000) . To install remaining components, reverse removal procedure.

Scheme 29