RX400h · Service Manual ENGINE

REMOVAL

Removal / installation


1. REMOVE ENGINE ROOM SIDE LH COVER

  1. A108719
    Using a clip remover, remove the engine room side cover.


2. REMOVE ENGINE ROOM COVER SIDE

  1. A109835
    Remove the 5 clips and engine room cover side.


3. DRAIN COOLANT

  1. Remove the radiator cap.

    CAUTION:
    To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

  1. Drain the engine coolant by loosening the lower drain plug of the radiator and the cylinder block drain cock plugs.

    HINT:
    Engine coolant inside the radiator is drained from the drain hole located on the bottom of the engine under cover.

  1. Tighten the cylinder block drain cock plugs.

    Torque:
    13 N*m{ 133 kgf*cm , 9 in.*lbf }


    A108260E01


4. DRAIN ENGINE OIL

  1. Remove the oil filler cap.

  1. Remove the oil drain plug, and drain the oil into a container.

  1. Clean and install the oil drain plug with a new gasket.

    Torque:
    45 N*m{ 459 kgf*cm , 33 ft.*lbf }


5. REMOVE FRONT WHEEL RH

6. REMOVE ENGINE UNDER COVER NO.1

  1. A108722
    Remove the 6 bolts, 2 screws, 2 clips and engine under cover.


7. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

  1. A109417
    Remove the screw and separate the fender splash shield.


8. REMOVE FRONT FENDER APRON SEAL RH

  1. A108724
    Remove the 2 bolts, clip and fender apron seal RH.


9. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

  1. Remove the 2 nuts and the front wiper arm and blade assembly RH.


10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

  1. Remove the nut and the front wiper arm and blade assembly LH.


11. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

  1. E110470
    Remove the 2 clips.

  1. Disengage the 6 claws and the clamp, and remove the cowl top ventilator louver sub-assembly.


12. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

  1. E110471E01
    Disconnect the connector.

  1. Remove the 5 bolts and the windshield wiper motor and link assembly.

    HINT:
    Bolt <A> cannot be removed because it is integrated into windshield wiper link assembly.


13. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER

  1. A112528E01
    Separate the wire harness clamp and grommet (A).

  1. Remove the 4 shock absorber nuts (B).

  1. Remove the 4 bolts, 2 nuts and cowl top panel sub-assembly.

  1. Install the 4 shock absorber nuts.

    Torque:
    80 N*m{ 815 kgf*cm , 59 ft.*lbf }


14. REMOVE BATTERY

  1. Remove the bolt and battery clamp.

  1. Remove the battery and battery tray.


15. REMOVE BATTERY CARRIER SUB-ASSEMBLY

  1. A108128
    Remove the 5 bolts and battery carrier.


16. REMOVE COOL AIR INTAKE DUCT SEAL

  1. Remove the 4 clips and cool air intake duct seal.


17. REMOVE AIR CLEANER CAP W/ INLET

  1. A108124
    Remove the 2 bolts, 4 clamps and air cleaner cap w/ inlet.

  1. Remove the air cleaner filter element from the air cleaner case.


18. REMOVE AIR CLEANER CASE W/ RESONATOR

  1. A109893
    Separate the ventilation hose No.2.

  1. A109270
    Disconnect the MAF meter connector.

  1. Disconnect the 2 wire harness clamps from the air cleaner.

  1. A106878
    Remove the 5 bolts from the air cleaner case w/ resonator.

  1. A109570
    Remove the hose clamp, and separate the air cleaner hose No.1.

  1. Remove the air cleaner case w/ resonator.


19. REMOVE EMISSION CONTROL VALVE SET

  1. A109272E01
    Disconnect the VSV connector (A).

  1. Remove the wire harness clamp (B).

  1. Disconnect the fuel vapor feed hose No. 1 (C).

  1. Disconnect the fuel vapor feed hose No. 2 (D).

  1. Remove the 2 nuts (E), then remove the emission control valve set.


20. REMOVE INTAKE AIR SURGE TANK

  1. A106879E03
    Disconnect the throttle motor connector (A).

  1. Separate the water by-pass hose No. 2 (B).

  1. Separate the water by-pass hose No. 3 (C).

  1. Separate the fuel vapor feed hose (D).

  1. A109268
    Disconnect the ventilation hose.

  1. A109273E01
    Remove the 2 bolts, then remove the engine hanger No.1 (A).

  1. Remove the 2 bolts, then remove the surge tank stay No. 1 (B).

  1. Remove the 2 bolts, then remove the surge tank stay No. 2 (C).

  1. A109274E01
    Disconnect the ground cable connector.

  1. Using a socket hexagon wrench 8 mm, remove the 4 bolts.

  1. Remove the 2 nuts, then remove the emission control valve bracket and the intake air surge tank.

  1. Remove the gasket from the intake air surge tank.


21. DISCONNECT RADIATOR HOSE INLET

22. SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

  1. A108126
    Disconnect the connector.

  1. Remove the 2 bolts and separate the brake master cylinder reservoir.


23. REMOVE RESERVOIR BRACKET

  1. A108127
    Disconnect the clamp.

  1. Remove the nut, 2 bolts and reservoir bracket.


24. REMOVE AIR CLEANER BRACKET

  1. A108129
    Remove the 2 bolts and air cleaner bracket.


25. REMOVE ENGINE MOVING CONTROL ROD

  1. A108130
    Remove the 4 bolts, the engine moving control rod and the bracket.


26. REMOVE ENGINE MOUNTING STAY NO.2 RH

  1. A108727
    Remove the bolt, the engine mounting stay No.2 and the engine mounting bracket No.2.


27. REMOVE IGNITION COIL ASSEMBLY

28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

  1. A078541E01
    Remove the 2 engine wire harness clamps.

  1. Remove the 3 nuts and disconnect the engine wire harness.

  1. A108160
    Remove the 9 bolts and the cylinder head cover.


29. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

  1. A036719E01
    Using an E6 "torx" socket wrench, remove the 2 bolts and disconnect the engine wire harness protector.

  1. A114812
    Remove the 2 engine wire harness clamps.

    CAUTION:
    Wear insulating gloves.

  1. A108125
    Remove the 2 bolts and 2 brackets.

  1. A108159
    Remove the 9 bolts and the cylinder head cover.


30. REMOVE CRANKSHAFT PULLEY

  1. A108136E01
    Using SST, loosen the pulley bolt.
    SST
    09213-54015   (91651-60855)
    09330-00021  

  1. A108138E01
    Using SST and the pulley bolt, remove the pulley.
    SST
    09950-50013   (09951-05010, 09952-05010, 09953-05020, 09954-05031)

    NOTICE:
    Before using SST, apply lubricating oil to the threads and tip of the center bolt 150.


31. REMOVE TIMING BELT NO.1 COVER

  1. Remove the 4 bolts and the timing belt cover No.1.


32. REMOVE TIMING BELT NO.2 COVER

  1. A108158E01
    Disconnect the engine wire protector clamps from the timing belt No.2 cover.

  1. Remove the 5 bolts and the timing belt cover.


33. REMOVE ENGINE MOUNTING BRACKET RH

  1. A108728
    Remove the 2 bolts, 2 nuts and engine mounting bracket RH.


34. REMOVE TIMING BELT GUIDE NO.2

35. REMOVE TIMING BELT

  1. A078326E01
    Set No.1 cylinder to TDC/compression.

    1. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.

    2. Turn the crankshaft clockwise, and align the timing mark of the crankshaft timing pulley with the oil pump body.

    3. A005052E01
      Check that the timing marks of the camshaft timing pulleys and No.3 timing belt cover are aligned.
      If not, turn the crankshaft 1 revolution (360°).

    4. Remove the crankshaft pulley bolt.

  1. A052840E01
    If reusing the timing belt, check that there are 3 installation marks on the timing belt as shown in the illustration.

    1. If the installation marks have disappeared, put new installation marks on the timing belt before removing.

  1. A078327E01
    Set No.1 cylinder to approximately 60° BTDC/compression.

    1. Turn the crankshaft counterclockwise by approximately 60°.

      NOTICE:
      If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle.

  1. A078702E01
    Remove the timing belt tensioner.
    1st
    		 No.1 idler pulley
    2nd
    		 RH camshaft timing pulley
    3rd
    		 No.2 idler pulley
    4th
    		 LH camshaft timing pulley
    5th
    		 Water pump pulley
    6th
    		 Crankshaft timing pulley


36. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.2

  1. Remove the bolt and timing belt idler sub-assembly No.2


37. REMOVE CAMSHAFT TIMING PULLEY

  1. A108161E01
    Using SST, remove the bolt and the RH timing pulley.
    SST
    09960-10010   (09962-01000, 09963-01000)
    09249-63010  

  1. A108163E01
    Using SST, remove the bolt and the LH timing pulley.
    SST
    09960-10010   (09962-01000, 09963-01000)

    HINT:
    Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to the original locations when reassembling.


38. REMOVE TIMING BELT NO.3 COVER

  1. A108157E01
    Disconnect the 2 engine wire harness clamps from the timing belt No.3 cover.

  1. Remove the 6 bolts and the timing belt cover.


39. REMOVE CAMSHAFT

NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.

  1. A078706E01
    Align the timing marks (2-dot mark) of the camshaft drive and the driven gears by turning the camshaft with a wrench.

  1. A078707E01
    Secure the exhaust camshaft sub-gear to the main gear with a service bolt.

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

    Recommended service bolt: 
    Thread diameter
    		 6 mm
    Thread pitch
    		 1.0 mm
    Bolt length
    		 16 to 20 mm

    HINT:
    When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installing the service bolt.

  1. A078708E01
    Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the camshaft.

    NOTICE:
    1. Do not pry out the camshaft.
    2. Do not damage the portion of the cylinder head which receives the shaft thrust.


40. REMOVE NO.2 CAMSHAFT

  1. A078709E01
    Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the No.2 camshaft.

    NOTICE:
    1. Do not pry out the camshaft.
    2. Do not damage the portion of the cylinder head which receives the shaft thrust.

  1. Remove the oil seal from the No.2 camshaft.


41. REMOVE NO.3 CAMSHAFT SUB-ASSEMBLY

NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps should be carried out.

  1. A078710E01
    Align the timing marks (1-dot mark) of the camshaft drive and the driven gears by turning the camshaft with a wrench.

  1. A078711E01
    Secure the exhaust camshaft sub-gear to the main gear with a service bolt.

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

    Recommended service bolt: 
    Thread diameter
    		 6 mm
    Thread pitch
    		 1.0 mm
    Bolt length
    		 16 to 20 mm

    HINT:
    When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installing the service bolt.

  1. A078712E01
    Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the No.3 camshaft.

    NOTICE:
    1. Do not pry out the camshaft.
    2. Do not damage the portion of the cylinder head which receives the shaft thrust.


42. REMOVE NO.4 CAMSHAFT SUB-ASSEMBLY

  1. A078713E01
    Using several steps, loosen and remove the 10 bearing cap bolts uniformly in the sequence shown in the illustration. Remove the 5 bearing caps and the No.4 camshaft.

    NOTICE:
    1. Do not pry out the camshaft.
    2. Do not damage the portion of the cylinder head which receives the shaft thrust.

  1. Remove the oil seal from the No.4 camshaft.


43. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

NOTICE:
Do not remove or install the camshaft timing gear (VVT-i) unless the VVT-i or the camshaft needs to be replaced.

  1. A005739E01
    Clamp the camshaft in a vise on the hexagonal lobe.

    NOTICE:
    Do not damage the camshaft.

  1. A005740E01
    Using a 46 mm socket wrench, remove the lock nut by turning it clockwise.

    NOTICE:
    1. Remove it with the lock-pin engaged and locked at the most retard angle position.
    2. The lock nut has left-hand threads.
    3. Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.

  1. Remove the camshaft VVT-i.

    NOTICE:
    Never remove the 3 bolts on the gear.

    If it is difficult to remove the VVT-i, tap it lightly using a plastic-faced hammer and then remove it.


44. REMOVE CAMSHAFT SUB GEAR

  1. P012596E01
    Clamp the camshaft in a vise on the hexagonal lobe.

    NOTICE:
    Do not damage the camshaft.

  1. A078715E01
    Using SST, turn the sub-gear counterclockwise, and remove the service bolt.
    SST
    09960-10010   (09962-01000, 09963-00500)

  1. A052353E01
    Using snap ring pliers, remove the snap ring.

  1. A078732E01
    Remove the wave washer, camshaft sub-gear and camshaft gear bolt washer.

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