Lexus RX400h, Hybrid 3 2006

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the coolant from the engine radiator and hybrid transaxle.
  8.  
  9. Remove the service plug grip, found underneath the Battery Service cover on the rear seat. Wait 5 minutes to discharge the high voltage capacitor.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Right-hand front wheel
     
    Engine splash shields
     
    Right-hand front fender apron seal
     
    Wiper and blade assembly
     
    Top cowl ventilator louver assembly
     
    Wiper motor and link assembly
     
    Battery and battery tray
     
    Air intake assembly
     
    Converter with Inverter assembly
     
    Emission control valve set
     
    Intake air surge tank
     
    Fuel supply hose
     
    Heater inlet hose
     
    Intake manifold
     
    Radiator hoses
     
    Water outlet from the cylinder heads
     
    Brake master cylinder reservoir
     
    Air cleaner bracket
     
    Engine moving control rod
     
    Right-hand No.2 engine mounting stay
     
    Crankshaft pulley
     
    Timing belt No.1 and No.2 covers
     
    Right-hand engine mounting bracket
     
    Timing belt guide No.2
     
    Timing belt
     
    Timing belt No.2 idler
     
    Camshaft timing pulley
     
    Timing belt No.3 cover
     
    Front exhaust pipe assembly
     
    Exhaust manifold heat insulator
     
    Exhaust manifold stay
     
    Right-hand exhaust manifold and gasket
     
    Ignition coil
     
    Right-hand cylinder head cover
     
    Camshaft
     
    VVT sensor connector
     
    Camshaft timing oil control valve connecter
     

  12.  
  13. Loosen the right-hand cylinder head bolts in several steps in the sequence shown.

    Click image to see an enlarged view

    Fig. Right-hand cylinder head loosening sequence

  14.  
  15. Remove the cylinder head bolts and plate washers.
  16.  
  17. Remove the right-hand cylinder head and gasket.
  18.  
  19. Remove the manifold converter No.3 insulator.
  20.  
  21. Remove the exhaust manifold No.2 heat insulator.
  22.  
  23. Separate the cooling fan ECU and hang securely with mechanic-s wire.
  24.  
  25. Remove or disconnect the following:

    Left-hand exhaust manifold
     
    Oil level gauge guide
     
    Water inlet pipe
     
    Left-hand cylinder head cover
     
    Camshaft
     

  26.  
  27. Loosen the right-hand cylinder head bolts in several steps in the sequence shown.

    Click image to see an enlarged view

    Fig. Left-hand cylinder head loosening sequence

  28.  
  29. Remove the cylinder head bolts and plate washers.
  30.  
  31. Remove the left-hand cylinder head and gasket.
  32.  

To install:

  1. Install the left-hand cylinder head with a new gasket. Tighten the cylinder head bolts as follows:
    1. Step 1: Tighten the 8 cylinder head bolts to 40 ft. lbs. (54 Nm)
    2.  
    3. Step 2: Tighten each bolt 90°
    4.  
    5. Step 3: Tighten each bolt an additional 90°
    6.  
    7. Step 4: Tighten the single 8mm hexagon bolt to 14 ft. lbs. (19 Nm)

      Click image to see an enlarged view

      Fig. Left-hand cylinder head tightening sequence



      Click image to see an enlarged view

      Fig. 8mm hexagon bolt on the cylinder head

    8.  

  2.  
  3. Install or connect the following:

    Camshaft
     
    Left-hand cylinder head cover. Tighten to 71 inch lbs. (8 Nm).
     
    Water inlet pipe
     
    Oil level gauge guide. Tighten to 71 inch lbs. (8 Nm).
     
    Exhaust manifold No. 2 converter
     
    Cooling fan ECU
     
    Exhaust manifold No.2 heat insulator
     
    Manifold converter No.2 insulator
     

  4.  
  5. Install the right cylinder head with a new gasket. Tighten the cylinder head bolts as follows:
    1. Step 1: Tighten the 8 cylinder head bolts to 40 ft. lbs. (54 Nm)
    2.  
    3. Step 2: Tighten each bolt 90°
    4.  
    5. Step 3: Tighten each bolt an additional 90°
    6.  
    7. Step 4: Tighten the single 8mm hexagon bolt to 14 ft. lbs. (19 Nm)

      Click image to see an enlarged view

      Fig. Right-hand cylinder head tightening sequence

    8.  

  6.  
  7. The remainder of installation is the reverse order of removal.
  8.  
  9. Refill the engine oil to the correct level.
  10.  
  11. Refill the coolant to the engine radiator and hybrid transaxle to the correct level.
  12.  
  13. Replace the service plug grip.
  14.  
  15. Start the engine and check for leaks.
  16.  
  17. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  18.  

 
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