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Home >> Lexus >> 2006 >> GS 300 RWD V6-3.0L (3GR-FSE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Engine Removal and Installation >> Installation >> Part 1

Part 1

ENGINE ASSEMBLY

INSTALLATION





1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
a. Using a 19 mm deep socket wrench, remove the temperature sensor.
Torque: 20 Nm (204 kgf-cm 15 ft. lbs.)





2. INSTALL OIL PRESSURE SWITCH ASSEMBLY
a. Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm 11 ft. lbs.)

NOTICE: Do not start the engine within 1 hour after installation.

3. INSTALL ENGINE OIL LEVEL SENSOR
a. Install the engine oil level sensor and new gasket with the 4 bolts.
Torque: 7.0 Nm (71 kgf-cm 62 inch lbs.)

4. INSTALL IGNITION COIL ASSEMBLY
a. Install the 6 ignition coils with the 6 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

5. INSTALL OIL FILLER CAP SUB-ASSEMBLY
6. INSTALL ENGINE MOUNTING BRACKET RH
a. Install the mounting bracket with the 4 bolts.
Torque: 43 Nm (438 kgf-cm 32 ft. lbs.)

7. INSTALL ENGINE MOUNTING BRACKET LH
a. Install the mounting bracket with the 4 bolts.
Torque: 43 Nm (438 kgf-cm 32 ft. lbs.)





8. INSTALL KNOCK SENSOR
a. Install the 2 knock sensors so that they are horizontal as shown in the illustration. Then install the 2 bolts.
Torque: 20 Nm (204 kgf-cm 15 ft. lbs.)

HINT: It is acceptable for the sensor to be tilted +10° to -5°.

9. INSTALL FUEL INJECTOR ASSEMBLY
10. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
11. INSTALL NO.2 FUEL DELIVERY PIPE SUB-ASSEMBLY
12. INSTALL HIGH PRESSURE SIDE FUEL PUMP
13. INSTALL NO.2 FUEL PIPE SUB-ASSEMBLY
14. INSTALL NO.1 FUEL PIPE SUB-ASSEMBLY
15. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY





16. INSTALL INTAKE MANIFOLD
a. Install a new gasket and the intake manifold with the 4 bolts and 2 nuts.
Torque: 21 Nm (214 kgf-cm 15 ft. lbs.)





17. INSTALL INTAKE AIR SURGE TANK SUB-ASSEMBLY
a. Install a new gasket to the intake air surge tank.
b. Install the intake air surge tank with the 2 nuts.
Torque: 18 Nm (184 kgf-cm 13 ft. lbs.)
c. Using a hexagon socket wrench 5, install the 7 bolts.
Torque: 16 Nm (163 kgf-cm 12 ft. lbs.)
d. Install the 2 surge tank stays with the 4 bolts.
Torque: 21 Nm (214 kgf-cm 15 ft. lbs.)
e. Install the intake manifold stay with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

18. INSTALL NO.4 WATER BY-PASS PIPE
a. Install the water by-pass pipe with the bolt.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)

19. INSTALL NO.3 WATER BY-PASS PIPE
a. Install the water by-pass pipe with the bolt.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)





20. INSTALL REAR ENGINE COVER SUB-ASSEMBLY
a. Install the engine cover with the 3 clips.

21. CONNECT NO.2 WATER BY-PASS HOSE
22. CONNECT NO.1 WATER BY-PASS HOSE





23. INSTALL INJECTOR DRIVER
a. Install the injector driver with the bolt and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

24. INSTALL WATER PUMP PULLEY





25. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (for 2WD)
a. Temporarily install the V-ribbed belt tensioner with the 5 bolts.
b. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

Bolt Length:





c. Tighten the other bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)





26. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (for 4WD)
a. Temporarily install the V-ribbed belt tensioner with the 4 bolts.
b. Install the V-ribbed belt tensioner by tightening the bolt 1 in the order shown in the illustration.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

Bolt Length:





c. Tighten the other bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

27. INSTALL NO.2 IDLER PULLEY SUB-ASSEMBLY
a. Install the plate and idler pulley with the bolt.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

28. INSTALL FRONT DIFFERENTIAL ASSEMBLY
29. INSTALL GENERATOR ASSEMBLY





30. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Install a new gasket as shown in the illustration.





b. Install the exhaust manifold with the 6 nuts.
Torque: 21 Nm (214 kgf-cm 15 ft. lbs.)

NOTICE: Do not damage the stud bolt when installing the exhaust manifold.

HINT: First tighten either of the 2 nuts indicated by the arrows in the illustration.





31. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Install a new gasket as shown in the illustration.





b. Install the exhaust manifold with the 6 nuts.
Torque: 21 Nm (214 kgf-cm 15 ft. lbs.)

NOTICE: Do not damage the stud bolt when installing the exhaust manifold.

HINT: First tighten either of the 2 nuts indicated by the arrows in the illustration.





32. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
a. Install a new O-ring to the oil level gauge guide.
b. Apply a light coat of engine oil to the O-ring.
c. Push in the oil level gauge guide end into the guide hole.
d. Install the oil level gauge guide No.1 with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
e. Install the oil level gauge guide No.2 with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
f. Install the oil level gauge.

33. INSTALL ENGINE WIRE
a. Install the engine wire to the engine assembly

34. REMOVE ENGINE ASSEMBLY
a. Remove the bolts and engine from the engine stand.





35. INSTALL FRONT ENGINE MOUNTING INSULATOR
a. Install the front suspension crossmember sub assembly with the 2 bolts.
Torque: 35 Nm (357 kgf-cm 26 ft. lbs.)





36. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
a. Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021
b. Apply adhesive to 2 or 3 threads of the mounting bolts end.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent
c. Install the front spacer, drive plate and rear spacer on the crankshaft.





d. Install and tighten the 8 mounting bolts uniformly in several steps.
Torque: 83 Nm (850 kgf-cm 61 ft. lbs.)

NOTICE: Do not start the engine for at least 1 hour after installing.

37. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD)
38. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD)
39. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)
40. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD)





41. INSTALL ENGINE AND TRANSMISSION (for 2WD)
a. Remove the engine hanger No.1 and No.2.
b. Set the engine lifter.
c. Operate the engine lifter, then install the engine to the vehicle.





d. Install the engine and transmission with crossmember sub-assembly with the 12 bolts.
Torque:
167 Nm (1,700 kgf-cm, 123 ft. lbs.) for bolt A
204 Nm (2,080 kgf-cm, 150 ft. lbs.) for bolt B
50 Nm (510 kgf-cm, 37 ft. lbs.) for bolt C
49 Nm (500 kgf-cm, 36 ft. lbs.) for bolt D





e. Install the engine rear mounting member with the 4 bolts.
Torque: 26 Nm (265 kgf-cm 19 ft. lbs.)

42. INSTALL ENGINE AND TRANSMISSION (for 4WD)
a. Remove the engine hanger No.1 and No.2.
b. Set the engine lifter.
c. Operate the engine lifter, then install the engine to the vehicle.





d. Install the engine and transmission with crossmember sub-assembly with the 8 bolts.
Torque:
167 Nm (1,700 kgf-cm 123 ft. lbs.) for bolt A
165 Nm (1,683 kgf-cm 121 ft. lbs.) for bolt B
50 Nm (550 kgf-cm 37 ft. lbs.) for bolt C





e. Install the engine rear mounting member with the 4 bolts.
Torque: 26 Nm (265 kgf-cm 19 ft. lbs.)

43. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD)
44. INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUBASSEMBLY (for 4WD)
45. INSTALL POWER STEERING LINK WIRE HARNESS (for 2WD)
46. INSTALL NO.2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 2WD)
47. INSTALL NO.2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD)
48. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH (for 4WD)
49. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH (for 4WD)
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