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Home >> Lexus >> 2006 >> GS 300 RWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (3GR-FSE) >> Engine Assembly, Intake Manifold, Exhaust Manifold >> Removal

Engine Assembly, Intake Manifold, Exhaust Manifold: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  REMOVAL  ) 
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait for least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  3. REMOVE FRONT WHEELS 
  4. DRAIN ENGINE OIL (for 2WD) (See  REPLACEMENT  ) 
  5. DRAIN ENGINE OIL (for 4WD) (See  REPLACEMENT  ) 
  6. DRAIN ENGINE COOLANT (See  ON-VEHICLE INSPECTION  ) 
  7. DRAIN AUTOMATIC TRANSMISSION FLUID (for 2WD) (See  REMOVAL  ) 
  8. DRAIN AUTOMATIC TRANSMISSION FLUID (for 4WD) (See  REMOVAL  ) 
  9. DRAIN FRONT DIFFERENTIAL OIL (for 4WD) 
    1. Drain the differential oil plug.
  10. REMOVE COOL AIR INTAKE DUCT SEAL 
    1. Remove the 7 clips and intake duct seal.
      Fig 1: Identifying Clips And Intake Duct Seal
      G04018164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE ENGINE ROOM COVER SIDE RH 
    1. Remove the nut, 2 clip and side cover.
      Fig 2: Identifying Engine Room Cover Side Rh
      G04018165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE ENGINE ROOM SIDE COVER LH 
    1. Remove the 3 clips and side cover.
      Fig 3: Identifying 3 Clips And Side Cover
      G04018166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Remove the 2 nuts and V-bank cover.
      Fig 4: Identifying Nuts And V-Bank Cover
      G04018167Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE ENGINE UNDER COVER (See  REMOVAL  ) 
  15. REMOVE NO. 2 ENGINE UNDER COVER (for 2WD) 
    1. Remove the 4 screws, 2gromets, 2 spacers and under cover.
  16. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See  REMOVAL  ) 
  17. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (See  REMOVAL  ) 
  18. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) (See  INSTALLATION  ) 
  19. REMOVE NO. 1 AIR CLEANER INLET 
    1. Remove the bolt and air cleaner inlet.
      Fig 5: Identifying Bolt And Air Cleaner Inlet
      G04018168Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE AIR CLEANER ASSEMBLY WITH HOSE 
    1. Disconnect the ventilation hose from the cylinder head.
      Fig 6: Locating Ventilation Hose To Cylinder Head Cover
      G04018097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the MAF meter connector.
    3. Disconnect the clamp from the air cleaner.
    4. Disconnect the EVAP VSV.
    5. Loosen the hose clamp.
    6. Remove the 3 bolts and air cleaner case.
      Fig 7: Identifying Bolts And Air Cleaner Case
      G04018170Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT RADIATOR HOSE INLET (See  REMOVAL  ) 
  22. DISCONNECT RADIATOR HOSE OUTLET (See  REMOVAL  ) 
  23. DISCONNECT RADIATOR RESERVE TANK HOSE 
    Fig 8: Identifying Radiator Hose Inlet
    G04018171Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Remove the clamp and disconnect the union to check valve hose.
      Fig 9: Identifying Clamp And Disconnect Union To Check Valve Hose
      G04018172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT HEATER WATER INLET HOSE A 
    1. Disconnect the inlet hose.
      Fig 10: Identifying Inlet Hose
      G04018173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT HEATER WATER OUTLET HOSE A 
    1. Disconnect the outlet hose.
  27. DISCONNECT FUEL MAIN TUBE (See  REMOVAL  ) 
    Fig 11: Identifying Fuel Main Tube
    G04018174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE ENGINE ROOM ECM COVER 
    1. Remove the 3 bolts and engine room ECM cover.
      Fig 12: Locating ECM Cover Mounting Bolts
      G04027244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. DISCONNECT ENGINE WIRE 
    1. Disconnect the ECM connectors.
    2. Using a screwdriver, disconnect the connector holder.
    3. Disconnect the 6 ECM connectors.
    4. Remove the nut and disconnect the battery positive (+) cable.
    5. Remove the engine room No. 1 relay block, junction block cover.
      Fig 13: Identifying Engine Room Relay Block
      G04018176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the nut and disconnect the wire from the engine room No. 1 relay block, junction block.
    7. Remove the bolt and disconnect the ground cable.
  30. REMOVE FAN AND GENERATOR V BELT (See  REMOVAL   ) 
    Fig 14: Identifying Fan And Generator V Belt
    G04018177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. DISCONNECT WITH PULLEY COMPRESSOR ASSEMBLY (for 2WD) 
    1. Disconnect the magnetic clutch connector.
    2. Remove the 3 bolts and nut.
      Fig 15: Identifying Magnetic Clutch Connector
      G04018178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using an E8 "Torx" socket, remove the stud bolt and with pulley compressor.

      HINT:

      It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

      Fig 16: Identifying Stud Bolt And With Pulley Compressor
      G04018179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. DISCONNECT WITH PULLEY COMPRESSOR ASSEMBLY (for 4WD) 
    1. Remove the bolt, nut and bracket.
      Fig 17: Identifying Pulley Compressor Assembly
      G04018180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the magnetic clutch connector.
    3. Remove the 2 bolts and nut.
      Fig 18: Identifying Magnetic Clutch Connector
      G04018181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using an E8 "Torx" socket, remove the stud bolt and with pulley compressor.

      HINT:

      It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

      Fig 19: Identifying Stud Bolt And With Pulley Compressor
      G04018182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. DISCONNECT HEIGHT CONTROL SENSOR LINK 
    1. Remove the nut and disconnect the height control sensor link.
  34. REMOVE FRONT SUSPENSION MEMBER PROTECTOR LOWER (for 2WD) 
    1. Remove the 4 bolts and protector.
  35. REMOVE FRONT AXLE HUB NUT RH (for 4WD) (See  REMOVAL  ) 
  36. REMOVE FRONT AXLE HUB NUT LH (for 4WD) (See  REMOVAL  ) 
  37. REMOVE TIE ROD ASSEMBLY RH (for 2WD) (See  REMOVAL  ) 
  38. REMOVE TIE ROD ASSEMBLY LH (for 2WD) (See  REMOVAL  ) 
  39. REMOVE TIE ROD ASSEMBLY RH (for 4WD) (See  REMOVAL  ) 
  40. REMOVE TIE ROD ASSEMBLY LH (for 4WD) (See  REMOVAL  ) 
  41. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD) (See  REMOVAL  ) 
  42. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD) (See  REMOVAL  ) 
  43. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH (for 4WD) (See  REMOVAL  ) 
  44. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH (for 4WD) (See  REMOVAL  ) 
  45. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH (for 4WD) (See  REMOVAL  ) 
  46. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH (for 4WD) (See  REMOVAL  ) 
  47. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 2WD) (See  REMOVAL  ) 
  48. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD) (See  REMOVAL  ) 
  49. DISCONNECT POWER STEERING LINK WIRE HARNESS (for 2WD) (See  REMOVAL  ) 
  50. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD) (See  REMOVAL  ) 
  51. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 4WD) (See  REMOVAL  ) 
  52. REMOVE ENGINE AND TRANSMISSION (for 2WD) 
    1. Set the engine lifter.
    2. Remove the 4 bolts, then separate the engine rear mounting member.
      Fig 20: Locating Engine Rear Mounting Member Retaining Bolts
      G04018227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 12 bolts shown in the illustration.
    4. Operate the engine lifter, then slowly remove the engine from the vehicle.
      NOTE: Make sure the engine is clear of all wiring and hoses.
      Fig 21: Identifying Engine From Vehicle
      G04018184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 2 engine hangers with the 4 bolts as shown in the illustration.

      Part No.: 

      PART NUMBER DESCRIPTION

      Engine hanger No. 1 12281 - 31070
      Engine hanger No. 2 12282 - 31070
      Bolts 91671 - 10825

      Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf) 

    6. Attach an engine sling device and hang the engine a the chain block.
      Fig 22: Attaching Engine Sling Device And Hang Engine A Chain Block
      G04018185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE ENGINE AND TRANSMISSION (for 4WD) 
    1. Set the engine lifter.
    2. Remove the 4 bolts, then separate the engine rear mounting member.
      Fig 23: Locating Engine Rear Mounting Member Retaining Bolts
      G04018227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 8 bolts shown in the illustration.
    4. Operate the engine lifter, then slowly remove the engine and transmission with crossmember subassembly from the vehicle.
      NOTE: Make sure the engine is clear of all wiring and hoses.
      Fig 24: Identifying Bolts
      G04018187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the 2 engine hangers with the 4 bolts as shown in the illustration.

      Part No.: 

      PART NUMBER DESCRIPTION

      Engine hanger No. 1 12281 - 31070
      Engine hanger No. 2 12282 - 31070
      Bolts 91671 - 10825

      Torque: 33 N*m (336 kgf*cm, 24 ft.*lbf) 

    6. Attach an engine sling device and hang the engine with a chain block.
      Fig 25: Attaching An Engine Sling Device And Hang Engine With A Chain Block
      G04018188Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) (See  REMOVAL  ) 
  55. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD) (See  REMOVAL  ) 
  56. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) (See  REMOVAL  ) 
  57. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) (See  REMOVAL  ) 
  58. REMOVE DRIVE PLATE AND RING GEAR SUBASSEMBLY 
    1. Using SST, hold the crankshaft.

      SST 09213-70011 (09213-70020), 09330-00021 

      Fig 26: Identifying Drive Plate And Ring Gear Subassembly
      G04018189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts, front spacer, drive plate and rear spacer.
      Fig 27: Identifying, Front Spacer, Drive Plate And Rear Spacer
      G04018190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE FRONT ENGINE MOUNTING INSULATOR 
    1. Remove the 2 bolts, then remove the front suspension crossmember sub-assembly from the engine.
  60. FIX ENGINE ON ENGINE STAND 
    1. Fix the engine onto a engine stand with the bolts.
      Fig 28: Identifying Fix Engine Onto A Engine Stand With Bolts
      G04018191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine.
  62. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY 
    1. Remove the oil level gauge.
    2. Remove the 2 bolts, then remove the oil level gauge guide No. 1 and No. 2.
    3. Remove the O-ring from the oil level gauge guide.
  63. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Disconnect the heated oxygen sensor connector.
    2. Remove the 6 nuts, exhaust manifold and gasket.
      Fig 29: Identifying Exhaust Manifold And Gasket
      G04018192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.

      Maximum warpage: 

      0.7 mm (0.028 in.) 

      HINT:

      The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.).

      If the warpage is greater than the maximum, replace the manifold.

      Fig 30: Inspecting Exhaust Manifold Sub-Assembly Rh
      G04018193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Disconnect the heated oxygen sensor connector.
    2. Remove the 6 nuts, exhaust manifold and gasket.
  66. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.

      Maximum warpage: 

      0.7 mm (0.028 in.) 

      HINT:

      The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.).

      If the warpage is greater than the maximum, replace the manifold.

      Fig 31: Inspecting Exhaust Manifold Sub-Assembly LH
      G04018194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. REMOVE GENERATOR ASSEMBLY (See  REMOVAL  ) 
  68. REMOVE FRONT DIFFERENTIAL ASSEMBLY (for 4WD) (See  REMOVAL  ) 
  69. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Remove the bolt, plate and idler pulley.
  70. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (for 2WD) 
    1. Remove the 5 bolts, then remove the V-ribbed belt tensioner assembly.
      Fig 32: Identifying V-Ribbed Belt Tensioner Assembly
      G04018195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (for 4WD) 
    1. Remove the 4 bolts, then remove the V-ribbed belt tensioner assembly.
  72. REMOVE WATER PUMP PULLEY (See  REMOVAL  ) 
    Fig 33: Identifying Water Pump Pulley
    G04018196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. REMOVE INJECTOR DRIVER 
    1. Remove the bolt, 2 nuts and injector driver.
  74. DISCONNECT NO. 1 WATER BYPASS HOSE 
  75. DISCONNECT NO. 2 WATER BYPASS HOSE 
    Fig 34: Identifying Injector Driver, Bolt And Nuts
    G04055976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. REMOVE REAR ENGINE COVER SUB-ASSEMBLY 
    1. Remove the 3 clips and engine cover.
  77. REMOVE NO. 3 WATER BYPASS PIPE 
    1. Remove the bolt and water bypass pipe.
  78. REMOVE NO. 4 WATER BYPASS PIPE 
    1. Remove the bolt and water bypass pipe.
      Fig 35: Identifying Bolt And Water By-Pass Pipe
      G04018198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE INTAKE AIR SURGE TANK SUBASSEMBLY 
    1. Remove the 2 bolts and intake manifold stay.
    2. Remove the 4 bolts and 2 surge tank stays.
    3. Using a 5 mm hexagon socket wrench, remove the 7 bolts, 2 nuts and gasket.

      HINT:

      Cover the intake manifold port to prevent foreign matter from entering it.

      Fig 36: Identifying Intake Air Surge Tank Subassembly
      G04018199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. INSPECT INTAKE AIR SURGE TANK SUBASSEMBLY 
    1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.

      Maximum warpage: 

      PART NUMBER DESCRIPTION

      0.3 mm (0.011 in.) When installed
      2.5 mm (0.098 in.) When not installed

      If the warpage is greater than the maximum, replace the surge tank.

      Fig 37: Replacing Surge Tank
      G04018200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. REMOVE INTAKE MANIFOLD 
    1. Remove the 4 bolts, 2 nuts, intake manifold and gasket.

      HINT:

      Cover the cylinder head intake port to prevent foreign matter from entering it.

      Fig 38: Identifying Intake Manifold And Gasket
      G04018201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. INSPECT INTAKE MANIFOLD 
    1. Surge tank side:
      1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.

        Maximum warpage: 

        0.1 mm (0.003 in.) 

        If the warpage is greater than the maximum, replace the intake manifold.

    2. Cylinder head side:
      1. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.

        Maximum warpage: 

        0.1 mm (0.003 in.) 

        If the warpage is greater than the maximum, replace the intake manifold.

        Fig 39: Inspecting Intake Manifold
        G04018202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY (See  REMOVAL  ) 
  84. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY (See  REMOVAL  ) 
  85. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY (See  REMOVAL  ) 
  86. REMOVE HIGH PRESSURE SIDE FUEL PUMP (See  REMOVAL  ) 
  87. REMOVE NO. 2 FUEL DELIVERY PIPE SUBASSEMBLY (See  REMOVAL  ) 
  88. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (See  REMOVAL  ) 
  89. REMOVE FUEL INJECTOR ASSEMBLY (See  REMOVAL  ) 
  90. REMOVE KNOCK SENSOR 
    1. Remove the 2 bolts and 2 sensors.
  91. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 4 bolts and mounting bracket.
  92. REMOVE ENGINE MOUNTING BRACKET LH 
    1. Remove the 4 bolts and mounting bracket.
  93. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
  94. REMOVE IGNITION COIL ASSEMBLY 
    1. Remove the 6 bolts and 6 ignition coils.
      Fig 40: Identifying Bolts And Ignition Coils
      G04018203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  95. REMOVE ENGINE OIL LEVEL SENSOR 
    1. Remove the 4 bolts, then remove the oil level sensor and gasket.
  96. REMOVE OIL PRESSURE SWITCH ASSEMBLY 
    1. Using a 24 mm deep socket wrench, remove the oil pressure switch.
      Fig 41: Identifying Oil Pressure Switch
      G04018204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  97. REMOVE ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using a 19 mm deep socket wrench, remove the temperature sensor.
      Fig 42: Identifying Temperature Sensor
      G04018205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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