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Home >> Lexus >> 2006 >> ES 330 V6-3.3L (3MZ-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Installation

Removal and Installation

PARTIAL ENGINE ASSEMBLY
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE FRONT WHEELS
4. REMOVE ENGINE UNDER COVER NO.1
5. REMOVE ENGINE UNDER COVER NO.2
6. REMOVE FRONT FENDER APRON SEAL RH
7. DRAIN ENGINE COOLANT
8. DRAIN ENGINE OIL
9. DRAIN AUTOMATIC TRANSAXLE FLUID
10. REMOVE V-BANK COVER SUB-ASSEMBLY
11. REMOVE RADIATOR LOWER AIR DEFLECTOR
12. REMOVE BATTERY
13. REMOVE BATTERY TRAY
14. REMOVE AIR CLEANER INLET ASSEMBLY
15. REMOVE AIR CLEANER ASSEMBLY
16. REMOVE AIR CLEANER BRACKET
17. REMOVE AIR CLEANER INLET NO.1
18. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY
a. Remove the clip and bolt, then remove the intake air resonator.
19. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
20. REMOVE GENERATOR ASSEMBLY
21. REMOVE ENGINE MOVING CONTROL ROD
22. REMOVE ENGINE MOUNTING STAY NO.2 RH
23. REMOVE GENERATOR BRACKET NO.2
24. REMOVE GENERATOR BELT ADJUSTING BAR
25. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
26. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY
27. DISCONNECT UNION TO CHECK VALVE HOSE
28. DISCONNECT FUEL VAPOR FEED HOSE NO.1
29. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO.1
30. DISCONNECT HEATER INLET WATER HOSE
31. DISCONNECT HEATER OUTLET WATER HOSE
32. DISCONNECT RADIATOR HOSE INLET
33. DISCONNECT RADIATOR HOSE OUTLET
34. DISCONNECT OIL COOLER INLET HOSE
35. DISCONNECT OIL COOLER OUTLET HOSE





36. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1





37. DISCONNECT STEERING GEAR OUTLET RETURN TUBE
38. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY
39. SEPARATE ENGINE WIRE
a. Disconnect the engine wire harness from the ECM and junction block.





b. Disconnect the engine wire harness from the engine room junction block.
1. Remove the nut, then separate the engine wire harness.
2. Using a screwdriver, release the engine room junction block. Separate the engine wire harness by pulling it upward.
c. Remove the 2 nuts, then pull out the engine wire harness.
d. Remove the body ground.
40. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT
41. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR
42. REMOVE EXHAUST PIPE ASSEMBLY FRONT
43. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH
44. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

45. REMOVE FRONT AXLE HUB LH NUT
SST 09930-00010
46. REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010

HINT: Perform the same procedure as above on the opposite side.

47. SEPARATE SPEED SENSOR FRONT LH
48. SEPARATE SPEED SENSOR FRONT RH

HINT: Perform the same procedure as above on the opposite side.

49. SEPARATE TIE ROD ASSEMBLY LH
SST 09628-62011
50. SEPARATE TIE ROD ASSEMBLY RH
SST 09628-62011

HINT: Perform the same procedure as above on the opposite side.

51. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
52. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT: Perform the same procedure as above on the opposite side.

53. SEPARATE FRONT AXLE ASSEMBLY LH
54. SEPARATE FRONT AXLE ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

55. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY
56. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter.





b. Remove the 4 bolts and 2 nuts, then remove the frame side rail plate RH and LH.





c. Remove the 4 bolts and 2 nuts, then remove the front suspension member brace rear RH and LH.
d. Carefully remove the engine assembly from the vehicle.





e. Install the engine hanger No. 2 in the correct direction as shown in the illustration.
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)





HINT:

f. Attach the engine sling and hang the engine assembly with the chain block.
57. REMOVE VANE PUMP V BELT
58. REMOVE VANE PUMP ASSEMBLY





a. Remove the 2 nuts, then disconnect the power steering pressure tube.





b. Remove the 2 bolts and vane pump.
59. REMOVE FRONT FRAME ASSEMBLY





a. Remove the 2 nuts, then separate the engine mounting insulator RH and LH.





b. Remove the bolt, then separate the engine mounting insulator FR.
60. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
SST 09520-01010, 09520-24010 (09520-32040)
61. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
62. REMOVE STARTER ASSEMBLY
63. REMOVE ENGINE MOUNTING BRACKET FR
64. REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1
65. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY
66. REMOVE DRIVE SHAFT BEARING BRACKET
67. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY
SST 09213-54015 (91651-60855), 09330-00021
68. INSTALL ENGINE STAND
69. REMOVE ENGINE HANGER NO.2
70. REMOVE EMISSION CONTROL VALVE SET
71. REMOVE INTAKE AIR SURGE TANK
72. REMOVE INTAKE MANIFOLD
73. REMOVE WATER OUTLET
74. REMOVE IGNITION COIL ASSEMBLY
75. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
76. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH





77. REMOVE MANIFOLD CONVERTER INSULATOR NO.3
a. Remove the bolt and nut, then remove the insulator.





78. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2
a. Remove the 2 bolts and insulator.





79. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2
a. Using several steps, loosen and remove the 7 nuts in the sequence shown in the illustration.
b. Remove the exhaust manifold converter No. 2 and gasket from the cylinder head LH.





80. REMOVE MANIFOLD STAY NO.2
a. Remove the 2 bolts and manifold stay.
81. REMOVE ENGINE MOUNTING BRACKET RH





82. REMOVE PUMP BRACKET
a. Remove the 3 bolts and pump bracket.
83. REMOVE GENERATOR BRACKET NO.1
84. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
85. REMOVE WATER INLET PIPE
86. REMOVE WATER INLET
87. REMOVE THERMOSTAT





88. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Using a deep socket wrench 24 mm, remove the oil pressure switch.
89. REMOVE KNOCK SENSOR
90. REPLACE PARTIAL ENGINE ASSEMBLY
91. INSTALL KNOCK SENSOR
92. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a deep socket wrench 24 mm, install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
93. INSTALL THERMOSTAT
94. INSTALL WATER INLET
95. INSTALL WATER INLET PIPE
96. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
97. INSTALL GENERATOR BRACKET NO.1
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
98. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
99. INSTALL ENGINE MOUNTING BRACKET RH
100. INSTALL MANIFOLD STAY NO.2
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





101. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2
a. Install a new gasket and the exhaust manifold converter No. 2 with the 7 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Retighten nuts 1 and 2 as shown in the illustration.
102. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
103. INSTALL MANIFOLD CONVERTER INSULATOR NO.3
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
104. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
105. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
106. INSTALL IGNITION COIL ASSEMBLY
107. INSTALL WATER OUTLET
108. INSTALL INTAKE MANIFOLD
109. INSTALL INTAKE AIR SURGE TANK
110. INSTALL EMISSION CONTROL VALVE SET
111. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
SST 09213-54015 (91651-60855), 09330-00021
112. INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 Nm (650 kgf-cm, 47 inch lbs.)
113. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
114. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1
115. INSTALL ENGINE MOUNTING BRACKET FR
116. INSTALL STARTER ASSEMBLY
117. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
118. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
119. INSTALL FRONT FRAME ASSEMBLY





a. Install the engine mounting insulator RH and LH with the 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)





b. Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)
120. INSTALL VANE PUMP ASSEMBLY





a. Temporarily tighten the bolt.
b. Install the adjusting strut to the engine mounting bracket RH with the bolt.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)





c. Connect the power steering pressure tube with the 2 nuts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
121. INSTALL VANE PUMP V BELT
122. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE





a. Set the engine assembly with the transaxle on the engine lifter.
b. Install the engine assembly to the vehicle.
c. Install the frame side rail plate RH and LH with the 4 bolts and 2 nuts.
Torque:
85 Nm (867 kgf-cm, 63 ft. lbs.) for bolt A
32 Nm (326 kgf-cm, 24 ft. lbs.) for bolt B and nut





d. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.
Torque:
85 Nm (867 kgf-cm, 63 ft. lbs.) for bolt C
32 Nm (326 kgf-cm, 24 ft. lbs.) for bolt D and nut
123. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY
124. INSTALL FRONT AXLE ASSEMBLY LH
125. INSTALL FRONT AXLE ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

126. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
127. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT: Perform the same procedure as above on the opposite side.

128. INSTALL TIE ROD ASSEMBLY LH
129. INSTALL TIE ROD ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

130. INSTALL SPEED SENSOR FRONT LH
131. INSTALL SPEED SENSOR FRONT RH

HINT: Perform the same procedure as above on the opposite side.

132. INSTALL FRONT AXLE HUB LH NUT
133. INSTALL FRONT AXLE HUB RH NUT

HINT: Perform the same procedure as above on the opposite side.

134. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
135. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

136. INSTALL EXHAUST PIPE ASSEMBLY FRONT
137. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR
138. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT
139. CONNECT FUEL PIPE SUB-ASSEMBLY NO.1
140. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
141. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
142. INSTALL GENERATOR BELT ADJUSTING BAR
143. INSTALL GENERATOR BRACKET NO.2
144. INSTALL ENGINE MOUNTING STAY NO.2 RH
145. INSTALL ENGINE MOVING CONTROL ROD
146. INSTALL GENERATOR ASSEMBLY
147. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
148. INSPECT DRIVE BELT DEFLECTION AND TENSION
149. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
150. INSTALL AIR CLEANER INLET NO.1
151. INSTALL AIR CLEANER BRACKET
152. INSTALL AIR CLEANER ASSEMBLY
153. INSTALL AIR CLEANER INLET ASSEMBLY





154. CHECK CONNECTION OF VACUUM HOSE
155. INSTALL V-BANK COVER SUB-ASSEMBLY
156. INSTALL FRONT WHEELS
157. ADD AUTOMATIC TRANSAXLE FLUID
158. ADD ENGINE OIL
159. ADD COOLANT
160. ADD POWER STEERING FLUID
161. BLEED POWER STEERING FLUID
162. INSPECT AUTOMATIC TRANSAXLE FLUID
163. CHECK FOR ENGINE OIL LEAKS
164. CHECK FOR ENGINE COOLANT LEAKS
165. CHECK POWER STEERING FLUID LEAKAGE
166. INSPECT FOR FUEL LEAKS
167. CHECK FOR EXHAUST GAS LEAKS
168. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
169. INSPECT STEERING WHEEL CENTER POINT
170. INSPECT IGNITION TIMING
SST 09843-18040
171. INSPECT ENGINE IDLE SPEED
172. INSPECT CO/HC
173. CHECK ABS SPEED SENSOR SIGNAL
174. SYSTEM INITIALIZATION

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