Lexus Car ES, IS, LS 1998-06

Timing Chain & Sprockets 3

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Removal & Installation



4gr-Fse & 2gr-Fse Engines

NOTE
The timing chain cannot be removed with the engine in the vehicle. The engine and transmission must be removed as a unit, then separated.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Engine/transmission assembly
     
    Front differential assembly (AWD)
     
    Serpentine drive belt
     
    No. 2 idler pulley
     
    Alternator
     
    A/C compressor unit, if necessary
     
    Left and right engine mounting brackets
     
    Serpentine belt tensioner
     
    Water pump pulley
     
    Fuel injector driver
     
    Intake air surge tank assembly and No. 2 surge tank stay
     
    Water hose joint
     
    Crankshaft pulley
     
    Water inlet
     
    Oil pan assembly
     
    Oil strainer
     
    No. 1 and 2 fuel pipes
     
    High pressure side fuel pump
     
    Ignition coil assembly
     
    No. 1 and 2 oil pipes
     
    Left and right cylinder head covers
     

  4.  
  5. Remove the timing chain cover and seal.
  6.  
  7. Set the No. 1 cylinder to TDC/compression as follows:
    1. Temporarily tighten the pulley set bolt.
    2.  
    3. Set the timing mark on the crank angle sensor plate to the right block bore center line (TDC/compression).
    4.  
    5. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap. If not, turn the crankshaft 1 revolution (360 degrees) and align the timing marks.

      Click image to see an enlarged view

      Fig. Aligning the timing marks at the block bore centerline and camshaft bearing caps-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines

    6.  

  8.  
  9. Remove the No. 1 chain tensioner assembly as follows:
    1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
    2.  
    3. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate-s hole.
    4.  
    5. Remove the 2 bolts and chain tensioner.

      Click image to see an enlarged view

      Fig. Chain tensioner component showing stopper plate and plunger-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines



      Chain tensioner slipper
       

    6.  

  10.  
  11. Remove the timing chain as follows:
    1. Turn the crankshaft counterclockwise 10 degrees to loosen the chain of the crankshaft timing sprocket.
    2.  
    3. Remove the pulley set bolt.
    4.  
    5. Remove the chain from the crankshaft timing sprocket and place it on the crankshaft.
    6.  
    7. Turn the camshaft timing gear assembly on the right bank clockwise (approx. 60 degrees). Be sure to loosen the chain between the banks.
    8.  
    9. Remove the timing chain.
    10.  

  12.  
  13. Remove or disconnect the following:

    No. 2 idle gear shaft, sprocket and No. 1 idle gear shaft
     
    2 bolts and No. 1 chain vibration damper
     
    Two No. 2 vibration dampers
     
    Crankshaft timing sprocket and 2 pulley set keys
     

  14.  

To install:

  1. Install or connect the following:

    No. 1 chain vibration damper and 2 bolts. Torque to 17 ft. lbs. (23 Nm).
     
    Two No. 2 vibration dampers
     
    Crankshaft timing sprocket and 2 pulley set keys
     

  2.  
  3. Install the idle sprocket assembly as follows:
    1. Apply a light coat of engine oil to the rotating surface of the No. 1 idle gear shaft.
    2.  
    3. Temporarily install the No. 1 idle gear shaft and idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block.
      NOTE
      Be careful of the idle gear direction.

    4.  
    5. Using a 10mm hexagon wrench, tighten the No. 2 idle gear shaft to 44 ft. lbs. (60 Nm). Check that the idle sprocket turns smoothly.
    6.  

  4.  
  5. Install the timing chain as follows:
    1. Align the mark plate and timing mark and install the chain.
    2.  
    3. Do not pass the chain over the crankshaft, just put it on it.
    4.  
    5. Turn the camshaft timing gear assembly on the right bank counterclockwise to tighten the chain between the banks.
      NOTE
      When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.

    6.  
    7. Align the mark plate and timing mark and install the chain onto the crankshaft timing sprocket.
    8.  
    9. Temporarily tighten the pulley set bolt.
    10.  
    11. Turn the crankshaft clockwise to set it to the right block bore center line (TDC/compression).

      Click image to see an enlarged view

      Fig. Aligning the mark plates to the timing marks-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines



      Chain tensioner slipper
       

    12.  

  6.  
  7. Install the No. 1 chain tensioner assembly as follows:
    1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
    2.  
    3. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
    4.  
    5. Install the chain tensioner with the 2 bolts and torque to 7 ft. lbs. (10 Nm).
    6.  
    7. Remove the lock pin of the chain tensioner. Check that each timing mark is aligned with the crankshaft at the TDC/compression.
    8.  
    9. Remove the pulley set bolt.
    10.  

  8.  
  9. Install or connect the following:

    Timing chain cover assembly
     
    Left and right cylinder head covers
     
    No. 1 and 2 oil pipes
     
    Ignition coil assembly
     
    High pressure side fuel pump
     
    No. 1 and 2 fuel pipes
     
    Oil strainer
     
    Oil pan assembly
     
    Water inlet
     
    Crankshaft pulley. Torque the bolt to 192 ft. lbs (260 Nm).
     
    Water hose joint
     
    Intake air surge tank assembly and No. 2 surge tank stay
     
    Fuel injector driver
     
    Water pump pulley. Torque the bolt to 15 ft. lbs (21 Nm).
     
    Serpentine belt tensioner
     
    Left and right engine mounting brackets
     
    A/C compressor unit, if necessary
     
    Alternator
     
    No. 2 idler pulley
     
    Serpentine drive belt
     
    Front differential assembly (AWD)
     
    Engine/transmission assembly
     

  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable. Wait at least 90 seconds before performing any other work
     
    Oil filler cap and gasket
     
    Radiator cap
     
    No. 1 and 2 engine hangers (3GR-FSE)
     
    Spark plugs
     
    Ventilation valve
     
    4 camshaft position sensors
     
    4 camshaft timing oil control valves
     
    Crankshaft position sensor
     
    Left and right side oil check valve bolt, oil pipe union and oil pipe
     
    Left and right side oil control valve filter and gaskets
     
    Cylinder block water drain cocks
     
    Oil filter element
     
    Water inlet and thermostat assembly
     
    Rear water by-pass joint
     
    Cylinder head cover and gaskets
     
    Timing chain cover, timing chain and timing chain sprockets
     
    No. 2 chain tensioner assembly
     

  10.  
  11. Remove the camshaft timing gears and No. 2 chain (right) as follows:
    1. While raising the No. 2 chain tensioner, insert a pin of 1.0mm (0.039 in.) into the hole to fix the No. 2 chain tensioner.
    2.  
    3. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.
    4.  
    5. Remove the No. 2 chain.

      No. 2 chain tensioner
       

    6.  

  12.  
  13. Remove the camshaft bearing cap (right) as follows:
    1. Check that the camshafts are positioned as shown in the illustration.
    2.  
    3. Uniformly loosen and remove the 9 bearing cap bolts in the sequence shown in the illustration.
    4.  
    5. Uniformly loosen and remove the 14 bearing cap bolts in the sequence shown in the illustration.
    6.  
    7. Remove the 6 bearing caps.
      WARNING
      Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.



      Click image to see an enlarged view

      Fig. Check that the camshafts are positioned as shown (right side)-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines



      Click image to see an enlarged view

      Fig. Right side camshaft bearing inner bolt loosening sequence-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines



      Click image to see an enlarged view

      Fig. Right side camshaft bearing outer bolt loosening sequence-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines



      Camshaft
       
      No. 2 camshaft
       
      Camshaft housing sub-assembly (right) by prying between the cylinder head and camshaft housing sub-assembly (right) with a screwdriver.
       

    8.  

  14.  
  15. Remove the camshaft timing gears and No. 2 chain (left) as follows:
    1. While pushing down the No. 3 chain tensioner, insert a pin of 1.0mm (0.039 in.) into the hole to fix the No. 3 chain tensioner.
    2.  
    3. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.
    4.  
    5. Remove the No. 2 chain.

      No. 3 chain tensioner
       

    6.  

  16.  
  17. Remove the camshaft bearing cap (left) as follows:
    1. Check that the camshafts are positioned as shown in the illustration.
    2.  
    3. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
    4.  
    5. Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration.
    6.  
    7. Remove the 5 bearing caps.
      WARNING
      Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.



      Click image to see an enlarged view

      Fig. Check that the camshafts are positioned as shown (left side)-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines



      Click image to see an enlarged view

      Fig. Left side camshaft bearing inner bolt loosening sequence-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines



      Click image to see an enlarged view

      Fig. Left side camshaft bearing outer bolt loosening sequence-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines



      No. 3 camshaft
       
      No. 4 camshaft
       
      Camshaft housing sub-assembly (left) by prying between the cylinder head and camshaft housing sub-assembly (left) with a screwdriver.
       



      Valve rocker arms. Arrange the removed rocker arms in the correct order.
       
      Valve lash adjusters. Arrange the removed valve lash adjusters in the correct order.
       

    8.  

  18.  

To install:

  1. Install valve lash adjusters as follows:
    WARNING
    Keep the lash adjuster free of dirt and foreign objects. Only use clean engine oil.

    1. Place the lash adjuster into a container filled with engine oil.
    2.  
    3. Insert the SST's tip (09276-75010) into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger as is shown.
    4.  
    5. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
    6.  
    7. Check the movement of the plunger and bleed the air.
    8.  
    9. After bleeding the air, remove SST. Then, try to quickly and firmly press the plunger with a finger. If the result is not as specified, replace the lash adjuster.
    10.  
    11. Install the lash adjusters.
      NOTE
      Install the lash adjuster to the same place it was removed from.



      Click image to see an enlarged view

      Fig. Bleeding air from the valve lash adjuster assembly-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines

    12.  

  2.  
  3. Install No. 1 valve rocker arm assembly as follows:
    1. Apply engine oil to the lash adjuster tip and valve stem cap end.
    2.  
    3. Make sure that the valve rocker arms are installed as shown in the illustration.

      Click image to see an enlarged view

      Fig. Correct installation of the valve rocker arm assembly-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines

    4.  

  4.  
  5. Install right side camshaft bearing cap as follows:
    1. Apply engine oil to the camshaft journals, camshaft housing and bearing caps.
    2.  
    3. Install the camshaft and camshaft No. 2 to the right camshaft housing.
    4.  
    5. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
    6.  
    7. Temporarily tighten the 9 bolts to 7 ft. lbs. (10 Nm) in the order shown in the illustration.

      Click image to see an enlarged view

      Fig. Make sure of the marks and numbers on the right camshaft bearing caps and place them in each proper position and direction.-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines



      Click image to see an enlarged view

      Fig. Temporarily tighten the 9 bolts in the order shown (right side).-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines

    8.  

  6.  
  7. Install the right side camshaft housing assembly as follows:
    1. Make sure that the valve rocker arm is installed as shown in the illustration.
    2.  
    3. Apply seal packing in a continuous line approximately 0.138-0.158 inches (3.5-4.0mm) wide.
      NOTE
      Remove any oil from the contact surface. Install the camshaft housing assembly within 3 minutes. Do not start the engine for at least 2 hours after installing.

    4.  
    5. Install the right camshaft housing and tighten the 14 bolts to 21 ft. lbs. (28 Nm) in the order shown in the illustration.
      WARNING
      When installing the camshaft housing, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing. If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.



      Click image to see an enlarged view

      Fig. Right camshaft housing assembly bolt tightening sequence and camshaft positioning.-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines



      Click image to see an enlarged view

      Fig. Right side camshaft bearing inner bolt tightening sequence-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines

    6.  
    7. Tighten the 9 bolts to 12 ft. lbs. (16 Nm) in the order shown in the illustration.
    8.  

  8.  
  9. Install left side camshaft bearing cap as follows:
    1. Apply engine oil to the camshaft journals, camshaft housing and bearing caps.
    2.  
    3. Install camshaft No. 3 and camshaft No. 4 to the left camshaft housing.
    4.  
    5. Make sure the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.
    6.  
    7. Temporarily tighten the 8 bolts to 7 ft. lbs. (10 Nm) in the order shown in the illustration.

      Click image to see an enlarged view

      Fig. Make sure of the marks and numbers on the left camshaft bearing caps and place them in each proper position and direction.-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines



      Click image to see an enlarged view

      Fig. Temporarily tighten the 8 bolts in the order shown (left side).-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines

    8.  

  10.  
  11. Install the left side camshaft housing assembly as follows:
    1. Make sure that the valve rocker arm is installed as shown in the illustration.
    2.  
    3. Apply seal packing in a continuous line approximately 0.197-0.217 inches (5.0-5.5mm) wide.
      NOTE
      Remove any oil from the contact surface. Install the camshaft housing assembly within 3 minutes. Do not start the engine for at least 2 hours after installing.

    4.  
    5. Install the left camshaft housing and tighten the 13 bolts to 21 ft. lbs. (28 Nm) in the order shown in the illustration.
      WARNING
      When installing the camshaft housing, it is necessary to correctly position the camshafts as shown in the illustration. Failure to correctly position these parts may result in damage due to contact between the pistons and valves. If a camshaft is rotated with a piston at TDC, valve contact will occur. If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing. If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.



      Click image to see an enlarged view

      Fig. Left camshaft housing assembly bolt tightening sequence and camshaft positioning.-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines



      Click image to see an enlarged view

      Fig. Left side camshaft bearing inner bolt tightening sequence-2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines

    6.  
    7. Tighten the 8 bolts to 12 ft. lbs. (16 Nm) in the order shown in the illustration.
    8.  

  12.  
  13. Install No. 2 chain tensioner assembly as follows:
    1. Install the No. 2 chain tensioner with the bolt. Torque the bolt to 15 ft. lbs. (21 Nm).
    2.  
    3. While pushing in the tensioner, insert a pin of 0.039 inch (1.0mm) into the hole to fix it.
    4.  

  14.  
  15. Install right side camshaft timing gears and No. 2 chain.
    1. Align the mark plate (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in the illustration.
    2.  
    3. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
    4.  
    5. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear (right) with the No. 2 chain installed.
    6.  
    7. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts to 74 ft. lbs. (100 Nm)
    8.  
    9. Remove the pin from the chain tensioner.

      Click image to see an enlarged view

      Fig. Align the mark plate with the timing marks of the camshaft timing gears (right side shown, left side similar) -2.5L (4GR-FSE), 3.0L (3GR-FSE) and 3.5L (2GR-FSE) Engines

    10.  

  16.  
  17. Install No. 3 chain tensioner assembly as follows:
    1. Install the chain tensioner with the bolt. Torque the bolt to 15 ft. lbs. (21 Nm).
    2.  
    3. While pushing in the tensioner, insert a pin of 0.039 inch (1.0mm) into the hole to hold it.
    4.  

  18.  
  19. Install left side camshaft timing gears and No. 2 chain.
    1. Align the mark plate (yellow) with the timing marks (2-dot mark) of the camshaft timing gears as shown in the illustration.
    2.  
    3. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
    4.  
    5. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear (left) with the No. 2 chain installed.
    6.  
    7. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts to 74 ft. lbs. (100 Nm)
    8.  
    9. Remove the pin from the chain tensioner.
    10.  

  20.  
  21. Install or connect the following:

    Timing chain cover, timing chain and timing chain sprockets
     
    Cylinder head cover and gaskets
     
    New gaskets, O-ring and rear water by-pass joint. Torque to 7 ft. lbs. (10 Nm).
     
    New gasket, water inlet and thermostat assembly. Torque to 7 ft. lbs. (10 Nm).
     
    Oil filter element
     
    Adhesive sealer, left and right side cylinder block water drain cocks. Torque to 22 ft. lbs. (30 Nm).
     
    Left and right side oil control valve filter and new gaskets
     
    Left and right side oil check valve bolt, oil pipe union and oil pipe. Torque to 44 ft. lbs. (60 Nm).
     
    Crankshaft position sensor. Torque to 7 ft. lbs. (10 Nm).
     
    4 camshaft timing oil control valves. Torque to 7 ft. lbs. (10 Nm).
     
    4 camshaft position sensors. Torque to 7 ft. lbs. (10 Nm).
     
    Adhesive and ventilation valve. Torque to 20 ft. lbs. (27 Nm).
     
    Spark plugs. Torque to 18 ft. lbs. (24 Nm).
     
    Engine hangers (if equipped). Torque to 24 ft. lbs. (33 Nm).
     
    Radiator cap
     
    Oil filler cap and gasket
     
    Negative battery cable
     

  22.  
  23. Refill the coolant and engine oil. Start the engine and check for leaks or abnormal conditions. Perform and road test. Then, recheck for leaks and recheck fluid levels.
  24.  

 
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