Lexus ES: Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during camshaft removal/installation are shown below.

PROCEDURE

1. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

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2. DISCONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY

(a) Disengage the 2 clamps and disconnect the air conditioning tube and accessory assembly.

3. DISCONNECT ENGINE WIRE

(a) Disconnect the 6 connectors.

(b) Disengage the 3 clamps and disconnect the engine wire.

4. REMOVE IGNITION COIL ASSEMBLY

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5. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

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6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

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7. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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8. REMOVE O-RING

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9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (EXHAUST CAMSHAFT TIMING GEAR BOLT ASSEMBLY)

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10. REMOVE CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

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11. REMOVE CAM TIMING CONTROL MOTOR O-RING

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12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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13. REMOVE SPARK PLUG TUBE GASKET

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14. REMOVE FUEL PUMP LIFTER GUIDE

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15. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

(a) Turn the crankshaft clockwise to align the timing mark (cutout) on the crankshaft pulley assembly with the "0" timing mark on the No. 2 timing chain cover assembly.

*a Paint Mark *b Timing Mark *c "0" Timing Mark

(b) Check that the timing marks are positioned as shown in the illustration.

HINT:

If the timing marks are not positioned as shown in the illustration, turn the crankshaft clockwise and then align them again.

(c) Place paint marks on the chain sub-assembly at points aligned with the timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

16. REMOVE STRAIGHT SCREW PLUG

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17. REMOVE CAMSHAFT

(a) Rotate the crankshaft approximately 15° clockwise.

*a Approximately 15°

(b) Rotate the crankshaft approximately 15° counterclockwise.

*a Approximately 15°

(c) Align the pin hole of the No. 1 chain tensioner assembly with the pin hole of the chain tensioner slipper, and then insert the pin.

*a Pin *b Pin Hole (No. 1 Chain Tensioner Assembly Side) *c Pin Hole (Chain Tensioner Slipper Side)

(d) Type A:

(1) Using the hexagonal portion of the No. 2 camshaft, secure the No. 2 camshaft. NOTICE: Do not damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube.

*a Hold

(2) Using a 5 mm hexagon wrench, remove the 2 bolts from the camshaft timing exhaust gear assembly.

(e) Type B:

(1) Using the hexagonal portion of the No. 2 camshaft, secure the No. 2 camshaft. NOTICE: Do not damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube.

*a Hold

(2) Using a 5 mm hexagon wrench, remove the 2 bolts from the camshaft timing exhaust gear assembly.

(f) Using the hexagonal portion of the camshaft, secure the camshaft.

*a	Hold
	Turn

(g) Using a 10 mm bi-hexagon socket wrench, remove the bolt from the camshaft timing gear assembly.

(h) Using the hexagonal portion of the No. 2 camshaft, loosen and hold the chain sub-assembly while moving the No. 2 camshaft in the direction shown in the illustration.

*a	Hold	-	-
	Turn	-	-

(i) Move the camshaft timing gear assembly together with the camshaft timing exhaust gear assembly and chain sub-assembly toward the No. 2 timing chain cover assembly as shown in the illustration.

*1	Camshaft Timing Gear Assembly	*2	Camshaft Timing Exhaust Gear Assembly
*3	Chain Sub-assembly	-	-
	Remove in this Direction	-	-

(j) Remove the camshaft timing exhaust gear assembly from the chain sub-assembly.

(k) Remove the camshaft timing gear assembly from the chain sub-assembly.

(l) Secure the chain sub-assembly to the vehicle using rope, etc. NOTICE: Do not drop the chain sub-assembly into the timing chain cover assembly.

(m) Uniformly loosen and remove the 8 bolts in the order shown in the illustration.

(n) Uniformly loosen and remove the 14 bolts in the order shown in the illustration. NOTICE: Uniformly loosen the bolts while holding the camshaft horizontally.

*1 No. 1 Camshaft Bearing Cap *2 No. 2 Camshaft Bearing Cap *3 No. 3 Camshaft Bearing Cap *4 No. 4 Camshaft Bearing Cap

(o) Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap.

HINT:

Arrange the removed parts so that they can be reinstalled in their original locations.

(p) Remove the camshaft from the camshaft housing sub-assembly.

(q) Remove the No. 2 camshaft from the camshaft housing sub-assembly.

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