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LEXUS RX 300

1998 — 2003 of release

Repair and car operation



RX 300 Lexus
+ Lexus RX-300 Cars
+ Governing bodies and operation receptions
+ Settings and routine maintenance of the car
- Engine
   General information and preparatory operations
   Check of kompressionny pressure
   Engine check by means of the vacuum gage
   Reduction of the piston of the first cylinder in the provision of the top dead point (VMT)
   Check of a corner of an advancing of ignition
   Removal, check and installation of a belt of a drive of GRM of its natyazhitel, pulley and cogwheel of a cranked shaft, cogwheels of camshafts and intermediate rollers
   Removal, dismantling, check, assembly and installation of a head of cylinders and its components
   Removal and engine installation, check of support
   Block of cylinders
   Check Д/В of pressure of impellent oil
   Removal, dismantling, check, assembly and installation of the oil pump and case pallet
+ Systems of cooling of the engine, heating, ventilation and air conditioning
+ the Power supply system and production of the fulfilled gases
+ Systems of electric equipment of the engine
+ Automatic transmission and interaxal differential
+ Transmission line
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment
+ Schematic diagrams of electric connections



Removal, dismantling, check, assembly and installation of a head of cylinders and its components

Removal

 PERFORMANCE ORDER

  1. Remove a windscreen fairing (see. Head Body).
  2. Empty system of cooling of the engine (see. The section Replacement of cooling liquid (OZh)).
  3. Remove a forward right wheel and a protective casing of a wing (1 on an illustration the Components which are subject to removal for access to a drive of GRM).
  4. Remove a belt of a drive of the generator (2 on an illustration the Components which are subject to removal for access to a drive of GRM) (see. Section Check of a condition and replacement of belts of a drive of auxiliary units).
  5. Remove the pump GUR (see. Head Suspension bracket and steering).
  6. Remove forward section of an exhaust pipe (see. Head of the Power supply system and production of the fulfilled gases).
  1. Remove a decorative cover of the engine.
  1. Remove air purifier assembly (see. Section Removal and air purifier installation)
  2. Remove the activator темпостата (4 on an illustration the Components which are subject to removal for access to a drive of GRM).
  3. Remove the top strut of an impellent compartment (9 on an illustration the Components which are subject to removal for access to a drive of GRM) (see. Head Body).

Components of installation of the air distributor and inlet pipeline

1 — the Pressure head tube of GUR
2 — an air distributor Rack
3 — the Elevating hook of No. of 1 engine
4 — the EVAP system VSV Socket
5 — a weight Cable
6 — the Vacuum hose of the amplifier of brakes
7 — the grounding Tyre
8 — the ECT Д/В Socket
9 — a PCV system Hose
10 — air distributor Assembly
11 — Laying
12 — the TPS Socket
13 — the IAC valve Socket
14 — the Cable of a drive of a butterfly valve

15 — Perepuskna a hose of system of cooling
16 — the Vacuum hose
17 — a purge Hose
18 — the Clip of a fuel hose
19 — the ACIS system VSV No. 1 Socket
20 — I Will corrode grounding tires
21 — the Clamp
22 — a heater Hose
23 — the Top hose of a radiator
24 — Assembly of the inlet pipeline
25 — the injector Socket
26 — the ignition Coil
27 — the Spark plug
28 — I Will corrode ignition coils
29 — the Water waste branch pipe


 PERFORMANCE ORDER

  1. Remove air distributor assembly. For this purpose execute the following operations:
    • Disconnect the following cables and electroconducting sockets:
      • Cable of a drive of a butterfly valve;
      • Socket and TPS sensor clamps;
      • IAC valve socket;
      • VSV No. 1 sockets and ACIS system No. 2;
      • EVAP system VSV socket.
    • Turn out three bolts and disconnect a pressure head tube of GUR from the air distributor, its rack and an elevating hook of No. of 1 engine.
    • Separate the following connections:
      • PCV hose from the PCV valve on a head of the right number of cylinders (1);
      • Cable of weight and the grounding tire from the valve of management of supply of air of ACIS (2) system;
      • Weight cable from the air distributor (3);
      • Vacuum hose of the amplifier of brakes from the air distributor (4);
      • Two perepuskny hoses of system of cooling from the case of a throttle (5);
      • Hose of a podmeshivaniye of air from the case of a throttle (6);
      • Purge hose from a tube on assembly of the valve of EVAP (7) system;
      • Two vacuum hoses from the vacuum chamber of ACIS system (8);
      • Collar of electroconducting of the engine from assembly of the valve of EVAP (9) system.

Connections which are subject to dismantling

(part 1)
(part 2)
    • Remove an elevating hook of No. of 1 engine and an air distributor rack.
    • Turn out two bolts, two nuts and remove the air distributor together with laying.
  1. Separate the following connections:
    • Sockets of injectors (No. 25);
    • Submitting fuel hose from a tube (No. 18) (observe work safety rules with fuel system);
    • Heater hose from the inlet pipeline (No. 22).
  1. Turn out 9 bolts and two nuts in sequence, return shown, remove two washers. Remove the inlet pipeline, fuel distributive highways and assembly of injectors.
  1. Disconnect from a water waste branch pipe (29) sockets (8 and 20) and the top hose of a radiator (23) then turn out two bolts and two nuts, remove two washers, disconnect perepuskny a hose (15) and remove a water waste branch pipe with two laying (11).
  2. Remove ignition and spark plug coils (see. Section Check and replacement of spark plugs).
  3. Remove a belt of a drive of GRM, cogwheels of camshafts and top (No. 2) an intermediate roller (see. Section Removal, check and installation of a belt of a drive of GRM of its natyazhitel, pulley and cogwheel of a cranked shaft, cogwheels of camshafts and intermediate rollers).
  4. Liberate a plait of electroconducting of the engine from three clips on a cover of No. 3 belts of a drive of GRM (No. 10), turn out 6 bolts of fastening of a cover and remove it.

Components of installation of final collectors, sensors and electroconducting

1 — Burn down engine electroconductings
2 — the Final collector of the right number of cylinders
3 — the Rack of a final collector of the right number of cylinders
4 — Laying
5 — the VVT-i system Valve
6 — the Back plate of a head of cylinders
7 — the Sealing ring
8 — a pump GUR Arm

9 — the CKP Sensor
10 — the Cover of No. 3 belts of a drive of GRM
11 — the Epiploon
12 — the Plug
13 — the Submitting water hose
14 — Directing щупа measurements of level of impellent oil
15 — the Rack of a final collector of the left number of cylinders
16 — the Final collector of the left number of cylinders


 PERFORMANCE ORDER

  1. Remove CMP (9) sensors and valves of management of GRM (5) greasing.
  2. Give fixture and disconnect protection of electroconducting of the engine against the back, right and left parties of a head of cylinders.
Fixture of a plait of electroconducting on the back party of a head of cylinders
Fixture of a plait of electroconducting on a head of the right number of cylinders
Fixture of a plait of electroconducting on a head of the left number of cylinders
  1. Turn out two bolts and remove a back plate (No. 6) of the left head of cylinders.
  2. Turn out a bolt and disconnect submitting tube (No. 13) from a reception branch pipe. Remove a sealing ring.
  3. Turn out three bolts and remove a pump GUR arm (No. 8).
  4. Disconnect from a final collector of the right number of cylinders electroconducting of the sensor of quality of an air and fuel mix (the row 1 sensor 1), remove a rack of a collector (No. 3) and, having given 6 nuts, remove a collector (No. 2).
  5. Remove the catalytic converter (No. 20 on an illustration the Components which are subject to removal for access to a drive of GRM).
  6. Disconnect from a final collector of the left number of cylinders electroconducting of the sensor of quality of an air and fuel mix (the row 2 sensor 1), remove a rack of a collector (No. 15) and, having given 6 nuts, remove a collector (No. 16).
  7. Turn out a bolt of fastening directing щупа level of impellent oil (No. 14) and extend directing together with shchupy and a sealing ring from the case pallet.
  8. Turn out on 9 bolts of fastening of covers (1 and 13) heads of cylinders (25 and 26) and remove covers together with laying.

Components of assembly of a head of cylinders

1 — the Cover of a head of the left number of cylinders
2 — Laying
3 — Laying of a candle opening
4 — the Washer of adjustment of a klapanny gap
5 — a valve Pusher
6 — Crackers of cutting locks
7 the Plate of a klapanny spring
8 Klapannaya a spring
9 — the Saddle of a klapanny spring
10 — Maslootrazhatelny a cap
11 — the Directing plug of the valve
12 — the Valve
13 — the Cover of a head of the right number of cylinders
14 — the Wavy washer
15 — the Spring of a gear wheel of a camshaft
16 — the Cutting lock ring

17 — the Additional gear wheel of a camshaft
18 — the Inlet camshaft of the right number of cylinders
19 — the Final camshaft of the right number of cylinders
20 — the Inlet camshaft of the left number of cylinders
21 — the Final camshaft of the left number of cylinders
22 — the Filter of the valve of VVT-i system
23 — the Back cover of a head of cylinders
24 — the Segment cap
25 — the Head of the left number of cylinders
26 — the Head of the right number of cylinders
27 — Laying of a head of the right number of cylinders
28 — the Cover of the bearing of a camshaft
29 — a camshaft Epiploon
30 — Laying of a head of the right number of cylinders
31 — the Camshaft
32 — the Rotor of shift of phases GRM (VVT-i)


 PERFORMANCE ORDER

  1. Remove an inlet camshaft of the right number of cylinders. For this purpose:
    • Combine adjusting labels (on two points; on shaft of the left number of cylinders – on one point) on gear wheels of inlet and final shaft, turning them an adjustable spanner for лыску on final to a shaft.
    • Fasten among themselves the main and additional gear wheels of a final camshaft bolt M6-1.0X16 (20), thereby having fixed a gear wheel spring.
    • In stages weaken and turn out 10 bolts of fastening of covers of bearings of a camshaft.
    • Remove 5 covers of bearings and a camshaft.
  1. In stages weaken and turn out 10 bolts of fastening of covers of bearings of a final camshaft of the right number of cylinders. Remove 5 covers of bearings and a camshaft.
  1. Remove inlet, and then final camshafts of the left number of cylinders, operating similar to removal of shaft of the right number of cylinders.
  2. The removed shaft and covers of their bearings arrange according to their adjusting situation that at assembly to establish them on former places.
  3. Consistently fix in a vice final camshafts for лыски under a wrench and disassemble shaft. For this purpose:
    • By means of the special adaptation turn an additional gear wheel counter-clockwise and turn out a bolt fastening it to the main gear wheel.
    • Compress nippers a cutting lock ring (No. 16) and remove it.
    • Remove a wavy washer (14), an additional gear wheel (17) and a spring of a gear wheel (15).

Do not mix the removed parts of final camshafts of the left and right number of cylinders.

  1. Remove heads of cylinders. For this purpose:
    • Turn out a prutkovy six-sided key on 8 mm the corresponding extreme bolt of fastening of each head of cylinders.
    • Evenly, in stages weaken and turn out 8 bolts of fastening of each head of cylinders strictly in sequence. Remove 16 bolts with washers.
    • Remove heads of cylinders from hairpins of the block of cylinders and lay them on wooden whetstones not to damage interfaced surfaces. If to remove heads of cylinders it is not possible manually, accurately hook them a screw-driver, trying not to damage interfaced surfaces of heads and the block of cylinders.

Dismantling

Do not remove from a camshaft a rotor of installation of phases GRM (VVT-i) if it is not supposed to replace a rotor or a shaft.


 PERFORMANCE ORDER

  1. Remove pushers of valves and adjusting washers. So that then them it was possible to establish their arrangement on former places.
  2. Remove valves. For this purpose:
    • Compress a klapanny spring and remove crackers of cutting locks.
    • Remove a plate of a spring, a spring and the valve.
    • Pull out nippers maslootrazhatelny caps.
    • By means of the compressed air and a magnet remove a spring saddle.
    • The removed components so that then them it was possible to establish an arrangement on former places.
  3. Turn out 6 bolts and remove a back cover of a head of cylinders and its laying (No. 23).
  1. Turn out a stopper and remove the filter of the valve of VVT-i system and its laying.
  1. Clamp in a vice a camshaft for лыски under a six-sided key, give a face key of 46 mm a nut of fastening of a rotor of VVT-i and remove a rotor, having if necessary brought down it a hammer with soft the brisk.

The nut has the left carving.

Do not turn out three bolts of a rotor.

Check

 PERFORMANCE ORDER

  1. Clear a soft scraper the top surfaces of pistons of coal deposits, clear interfaced surfaces of the block of cylinders and heads of cylinders of the laying remains then blow the dirt remains the compressed air and blow oil from carving openings under bolts of fastening of heads of cylinders.
  2. Clear a wire brush of the chamber of combustion of coal deposits then wash up heads of cylinders a soft brush with solvent.
  3. By means of a ramrod clear directing plugs of valves. Clear heads of valves of coal deposits then clear valves a soft brush.
  4. By means of an equal flat ruler measure not planeness of surfaces of heads of the cylinders interfaced to the block of cylinders. If necessary replace a head of cylinders.
  5. Measure internal diameter of directing plugs of valves, diameter of cores of valves (in several sections) then calculate an oil gap. Compare all obtained data with requirements of Specifications of Head the Engine, if necessary replace directing the plug and/or the valve.
  6. Measure a corner of a facet of the valve, height of a corbel of a head капана, full length of the valve and check the top surface of a core of the valve on wear. Compare all obtained data with requirements of Specifications of Head the Engine, if necessary replace the valve or grind the top surface of a core (but not less than till the minimum admissible length of a core!).
  1. Pierce saddles of valves at an angle the 45th hail. also check concentricity of saddles of valves and facets of valves, and also width of their interface. If necessary pierce a valve saddle.
  1. Leaning klapanny springs against a metal corner, will measure size of a deviation of an end face of a spring from a vertical. Will measure length of springs in a free condition then measure a spring tension at compression it till length of 33.8 mm. Compare all obtained data with requirements of Specifications of Head the Engine, if necessary replace klapanny springs.
  2. Will measure radial palpation of the central neck and diameter of necks of each camshaft. Measure height of cams and axial люфт camshafts. Compare all obtained data with requirements of Specifications of Head the Engine, if necessary replace a camshaft or check an oil gap of its bearings.
  3. Check bearings of camshafts on existence of otslaivaniye and jags. If necessary replace covers of bearings and a head of cylinders assembled.
  4. Clear necks of a cover of bearings of camshafts then measure an oil gap of bearings by means of Plastigage set, having tightened bolts of fastening of covers of bearings with effort of 16 Nanometers. Compare the obtained data with requirements of Specifications of Head the Engine and if necessary replace a camshaft and/or covers of bearings and a head of cylinders assembled.
  5. Establish camshafts without an additional gear wheel of a final camshaft and measure a dead course of gear wheels. If the measured value does not meet requirements of Specifications of Head the Engine, replace camshafts.
  6. Measure gap size in a spring ring of a gear wheel of a camshaft. If the measured value does not meet requirements of Specifications of Head the Engine, replace a spring.
  7. Measure diameter of a pro-point under a valve pusher, diameter of the pusher and calculate an oil gap of a pusher. Compare the obtained data with requirements of Specifications of Head the Engine and if necessary replace a pusher and/or a head of cylinders.
  8. By means of an equal flat ruler measure not planeness of interfaced surfaces of the air distributor, both interfaced surfaces of the inlet pipeline and an interfaced surface of final collectors. Compare the obtained data with requirements of Specifications of Head the Engine and if necessary replace the corresponding components.
  9. Measure diameter of a tension part of bolts of fastening of a head of cylinders with heads under a prutkovy key-shestigrannik. Compare the obtained data with requirements of Specifications of Head the Engine and if necessary replace bolts.

Assembly and installation

Before starting assembly and installation, make sure of purity of all components.


 PERFORMANCE ORDER

  1. If VVT-i rotor acted in film, establish it. For this purpose combine a pin on distributive to a shaft with a groove on a rotor, put on a rotor a shaft and tighten a nut of fastening of a rotor with effort of 150 Nanometers, previously having greased a carving with impellent oil.
  1. At installation of a new head of cylinders it is required to establish plugs of spark plugs and a PCV system tube. Plugs of spark plugs before installation grease with fixing hermetic (for example, Three Bond 1324) and press, having left to act on 42.4 ÷ 43.4 mm over an adjusting surface of a cover of the bearing of a camshaft. Tubes of PCV hammer with a hammer through wooden laying aflush with an interfaced surface of a head of cylinders.
Installation of the plug of a spark plug
Installation of a tube of PCV
  1. Establish the VVT-i valve filter together with laying (see No. 22) and tighten a filter stopper with effort of 45 Nanometers.
  2. Establish a back cover of a head of cylinders (see No. 23) and tighten bolts of its fastening with effort of 10 Nanometers.
  3. Establish valves in sequence, return sequence of their removal.

Maslootrazhatelnye caps of inlet valves have brown color, and final - gray.

  1. Establish pushers of valves and adjusting washers. Make sure that pushers smoothly rotate by hand in the landing nests.
  2. Establish on the block of cylinders two laying of heads of cylinders according to well-aimed on laying (L – left, R – right). Establish heads of cylinders.
  3. Consistently as it should be, the return specified illustrations, tighten on 8 bolts of fastening of each head of cylinders (with 12-faced heads) with effort of 54 Nanometers then hold on them in the same sequence on a corner the 90th hail.

Before a tightening of bolts grease their carving and the lower part of heads with a thin layer of impellent oil.

  1. Tighten bolts of fastening of heads of cylinders with heads under a prutkovy natural effort of 18 Nanometers.

Before a tightening of bolts grease their carving and the lower part of heads with a thin layer of impellent oil.

  1. Put on final camshafts a spring of an additional gear wheel, a gear wheel and a wavy washer then fix them a spring lock ring (No. No. 14-17).
  2. Turning an additional gear wheel clockwise by means of the special adaptation, combine openings in the main and additional gear wheels and temporarily screw in them an auxiliary bolt. Level teeths of the main and additional gear wheels and tighten a bolt.
  1. Grease necks of final camshafts with fresh impellent oil and lay them in a head of cylinders, having developed adjusting labels on a corner the 90th hail. up from the head plane.
  1. Grease with universal greasing sealing edges of a new forward epiploon and establish it on a camshaft.
  1. Clear covers of No. bearings of 1 camshafts of an old prokladochny material and put new hermetic (No. 08826-0080 according to the Toyota/Lexus catalog).
  1. Establish covers of bearings of final camshafts on their former places and with former orientation.

E1 type labels on covers of bearings designate number of the bearing of a final shaft, reading from GRM drive. The arrow near a label specifies towards GRM. Grease with a thin layer of impellent oil a carving and the lower part of heads of bolts of fastening of covers of bearings and evenly tighten bolts with effort of 16 Nanometers.


  1. Grease necks of inlet camshafts with fresh impellent oil, combine adjusting labels on the leader and conducted gear wheels and lay inlet camshafts in a head of cylinders.
  1. Establish covers of bearings of inlet camshafts on their former places and with former orientation.

I1 type labels on covers of bearings designate number of the bearing of an inlet shaft, reading from GRM drive. The arrow near a label specifies towards GRM. Grease with a thin layer of impellent oil a carving and the lower part of heads of bolts of fastening of covers of bearings and evenly, in stages, tighten bolts with effort of 16 Nanometers.

  1. Turn out an auxiliary bolt from gear wheels of a final camshaft.
  2. Check and if necessary adjust a klapanny gap (see. Section Check and adjustment of klapanny gaps).
  1. Establish segment jams (No. 24), previously having cleared them of an old sealing material and having put new (No. 08826-0080 according to the Toyota/Lexus catalog).
  1. Put hermetic (No. 08826-0080 according to the Toyota/Lexus catalog) on covers of heads of cylinders. Lay on heads of cylinders of laying and establish covers of heads of cylinders, having tightened their bolts evenly and in stages with effort of 8 Nanometers.
  1. Establish the following components, tightening their fixture with demanded efforts:
    • Final collector of the right number of cylinders and its rack;
    • Pump GUR arm;
    • Shchup of level of impellent oil together with its directing;
    • Final collector of the left number of cylinders and its rack;
    • Catalytic converter;
    • Submitting tube of system of cooling;
    • Back plate of a head of cylinders;
    • Protection of electroconducting of the engine;
    • VVT-i valves;
    • CKP sensors.

Use new sealing rings directing щупа level of impellent oil and a submitting tube of system of cooling.


  1. Examine laying of a cover of No. 3 belts of a drive of GRM. If integrity of laying is broken, replace it, previously having removed all traces of old laying and having cleared a cover surface. Remove from new laying a protective film or paper, establish laying exactly on a contour, and strongly press laying to a cover. Make sure that laying stuck to a cover.
  1. Establish a cover of No. 3 belts of a drive of GRM and tighten 6 bolts of its fastening with effort of 8.5 Nanometers.
  2. Establish a roller of No. 2 belts of a drive of GRM, cogwheels of camshafts and a belt of a drive of GRM (see. Section Removal, check and installation of a belt of a drive of GRM of its natyazhitel, pulley and cogwheel of a cranked shaft, cogwheels of camshafts and intermediate rollers).
  3. Establish spark plugs and ignition coils (see. Section Check and replacement of spark plugs).
  4. Establish two new laying of a water waste branch pipe (No. 29), connect to it perepuskny a hose, tighten branch pipe fixture with effort of 15 Nanometers and connect to a branch pipe ECT sensor electroconducting, the plug of the tire of grounding and a radiator hose.
  5. Establish the inlet pipeline, fuel distributive highways and injectors then evenly tighten 9 bolts and 2 nuts of fastening of the inlet pipeline with effort of 15 Nanometers.
  6. Connect a fuel submitting hose to a tube and a heater hose to the inlet pipeline.
  7. Make sure of that will tighten fixture of a water waste branch pipe with effort of 15 Nanometers.
  8. Establish air distributor assembly. All fixture tighten with demanded efforts. Use new laying of the air distributor.
  9. Establish the described components.
  10. Fill cooling system, start the engine and check it on leaks. Carry out a trial trip during which check make sure of absence of extraneous noise and pushes. Make sure of correctness of gear shifting and smoothness of a course of the car.
  11. Check level of OZh and if necessary modify it (see. The section Replacement of cooling liquid (OZh)).