IGNITION SYSTEM IGNITION SYSTEM IG0K5-04 ON-VEHICLE INSPECTION NOTICE: ”Cold” and ”Hot” in These Sentences Express the Temperature of the Coils Themselves

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IG-1 IGNITION - IGNITION SYSTEM IGNITION SYSTEM IG0K5-04 ON-VEHICLE INSPECTION NOTICE: ”Cold” and ”Hot” in these sentences express the temperature of the coils themselves. ”Cold” is from -10 °C (14°F) to 50°C (122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F). 1. INSPECT IGNITER AND SPARK TEST Check that the spark occurs. (1) Remove the ignition coil (See page IG-7 ). (2) Using a 16 mm plug wrench, remove the spark plug. (3) Install the spark plug to the ignition coil, and connect the ignition coil connector. (4) Ground the spark plug. (5) Check if spark occurs while engine is being cranked. NOTICE: To prevent excess fuel being injected from the injectors during this test, do not crank the engine for more 5 - 10 seconds at a time. If the spark does not occur, do the test as follows: SPARK TEST NO CHECK CONNECTION OF IGNITION COIL Connect securely. CONNECTOR BAD OK CHANGE IT TO NORMAL IGNITION COIL (WITH Replace the ignition coil (with igniter). IGNITER) AND PERFORM SPARK TEST AGAIN OK NO CHECK POWER SUPPLY TO IGNITION COIL (WITH Check wiring between ignition switch IGNITER) to ignition coil (with igniter). 1. Turn ignition switch to ON. 2. Check that there is battery voltage at ignition coil positive (+) BAD terminal. OK CHECK RESISTANCE OF CAMSHAFT POSITION Replace the camshaft position sensor. SENSOR (See step 3) Cold Hot BAD Resistance: 1,630 - 2,740 Ω 2,065 - 3.225 Ω OK CHECK RESISTANCE OF CRANKSHAFT POSITION Replace the crankshaft position sensor. SENSOR (See step 4) Cold Hot BAD Resistance: 985 - 1,600 Ω 1,265 - 1,890 Ω OK CHECK IGT SIGNAL FROM ECM Check ECM (See page IN-33 ) (See page DI-201 ) BAD OK REPAIR WIRING BETWEEN IGNITION COIL AND ECM

(6) Using a 16 mm plug wrench, reinstall the spark plug. Torque: 18 N·m (180 kgf·cm, 13 ft·lbf) (7) Reinstall the ignition coil (See page IG-9 ).

2005 LEXUS IS300 (RM1140U)

Author: Date: 1507 IG-2 IGNITION - IGNITION SYSTEM 2. INSPECT HIGH-TENSION CORDS WRONG (a) Remove the No.3 timing belt cover. (b) Remove the throttle body gasket (See page IG-7 ). CORRECT (c) Disconnect the high-tension cord set from the spark plugs. Disconnect the high-tension cords at the rubber boot. DO NOT pull on the cords. NOTICE:

B01621 Pulling on or bending the cords may damage the conductor inside. (d) Disconnect the high-tension cord set from the ignition coils. (1) Using a screwdriver, lift up the lock claw and disconnect the holder from the ignition coils. (2) Disconnect the high-tension cord at the grommet. DO NOT pull on the cord. NOTICE: S Pulling on or bending the cords may damage the conduc-

B01622 tor inside. S Do not wipe any of the oil from the grommet after the high- tension cord is disconnected.

(e) Using an ohmmeter, measure the resistance. Maximum resistance: 25 kΩ per cord If the resistance is greater than the maximum, check the termi- Ohmmeter nals. If necessary, replace the high-tension cord.

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(f) Reconnect the high-tension cord set to the ignition coils. (1) Assemble the holder and grommet. (2) Align the spline of the ignition coil with the spline of the holder, and push in the cord. Push

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2005 LEXUS IS300 (RM1140U)

Author: Date: 1508 IG-3 IGNITION - IGNITION SYSTEM NOTICE: Check that the holder is correctly installed to the grommet CORRECT as shown in the illustration. (3) Check that the lock claw of the holder is engaged by lightly pulling the holder. (g) Reconnect the high-tension cord set to the spark plugs. WRONG (h) Reinstall the throttle body gasket (See page IG-9 ). (i) Reinstall the No.3 timing belt cover.

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3. INSPECT SPARK PLUGS NOTICE: S Never use a wire brush for cleaning. S Never attempt to adjust the electrode gap on used a spark plug. (a) Remove the ignition coils and high-tension cord set assembly (See page IG-7 ).

(b) Inspect the electrode. Megger S Using a megger (insulation resistance meter), measure the insulation resistance. Standard correct insulation resistance: 10 MΩ or more If the resistance is less than specified, proceed to step (d). HINT: If a megger is not available, the following simple method of in-

Ground IG0147 spection provides fairly accurate results.

S Simple Method: S Quickly race the engine 5 times to 4,000 rpm. S Remove the spark plug (See step c). S Visually check the spark plug. If the electrode is dry ... OK If the electrode is wet ... Proceed to step (d) S Reinstall the spark plug (See step g). (c) Using a 16 mm plug wrench, remove the 6 spark plugs.

B02629 (d) Visually check the spark plug for thread damage and insu- lator damage. If abnormal, replace the spark plug. Recommended spark plug:

DENSO made SK16R-P11

2005 LEXUS IS300 (RM1140U)

Author: Date: 1509 IG-4 IGNITION - IGNITION SYSTEM (e) Inspect the electrode gap. Maximum electrode gap for used spark plug: 1.2 mm (0.047 in.) If the gap is greater than maximum, replace the spark plug. Correct electrode gap for new spark plug: 1.1 mm (0.043 in.) NOTICE: 1.0 - 1.1 mm If adjusting the gap of a new spark plug, bend only the base

B02630 of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on the used plug. (f) Clean the spark plugs. If the electrode has traces of wet carbon, allow it to dry and then clean with a spark plug cleaner. Air pressure: Below 588 kPa (6 kgf/cm2, 85 psi) Duration: 20 seconds or less HINT: If there are traces of oil, remove it with gasoline before using the spark plug cleaner.

IG0152 (g) Using a 16 mm plug wrench, reinstall the 6 spark plugs. Torque: 18 N·m (180 kgf·cm, 13 ft·lbf) (h) Reinstall the ignition coils and high-tension cord set assembly (See page IG-9 ). 4. INSPECT IGNITION COILS (a) Remove the ignition coil assembly (See page IG-7 ).

(b) Using an ohmmeter, measure the resistance between the Ohmmeter positive (+) and negative (-) terminals. Primary coil resistance:

Cold 0.33 - 0.52 Ω Hot 0.42 - 0.61 Ω If the resistance is not as specified, replace the ignition coil.

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(c) Using an ohmmeter, measure the resistance between the Ohmmeter positive (+) and high-tension terminal. Secondary coil resistance:

Cold 8.5 - 14.7 kΩ Hot 10.8 - 17.2 kΩ If the resistance is not as specified, replace the ignition coil. (d) Reinstall the ignition coil assembly (See page IG-9 ).

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2005 LEXUS IS300 (RM1140U)

Author: Date: 1510 IG-5 IGNITION - IGNITION SYSTEM

Ohmmeter 5. INSPECT CAMSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Using an ohmmeter, measure the resistance between terminals. Resistance:

Cold 835 - 1,400 Ω Hot 1,060 - 1,645 Ω If the resistance is not as specified, replace the sensor. B01626 (c) Reconnect the camshaft position sensor connector.

Ohmmeter 6. INSPECT CRANKSHAFT POSITION SENSOR (a) Disconnect the sensor connector. (b) Remove the bolt holding the connector bracket to the water pump. (c) Using an ohmmeter, measure the resistance between terminals. Resistance:

Cold 1,630 - 2,740 Ω B01627 Hot 2,065 - 3,225 Ω If the resistance is not as specified, replace the sensor. (d) Reinstall the bolt holding the connector bracket to the water pump. (e) Reconnect the sensor connector.

2005 LEXUS IS300 (RM1140U)

Author: Date: 1511 IG-6 IGNITION - IGNITION COIL IGNITION COIL IG05T-08 COMPONENTS

Oil Filler Cap

No. 3 Timing Belt Cover

PCV Hose Intake Air Resonator

Accelerator Pedal Position 21 (210, 15) Sensor Connector Throttle Body Engine Wire Clamp Accelerator Cable

PS Air Hose Throttle Body Throttle Control Gasket Motor Connector Throttle Body Bracket Throttle Position Sensor Connector Ignition Coil Connector 21 (210, 15) High-Tension Cord Set Engine Wire

No. 1

No. 3

No. 2

Ignition Coil

Water Bypass Hose

N·m (kgf·cm, ft·lbf) : Specified torque Hose Clamp B11954

2005 LEXUS IS300 (RM1140U)

Author: Date: 1512 IG-7 IGNITION - IGNITION COIL

IG05U-06 REMOVAL 1. REMOVE INTAKE AIR RESONATOR 2. REMOVE NO. 3 TIMING BELT COVER Using a 5 mm hexagon wrench, remove the 4 bolts, oil filler cap and No.3 timing belt cover. 3. DISCONNECT THROTTLE BODY FROM INTAKE AIR CONNECTOR WITHOUT DISCONNECTING WATER BYPASS HOSES (a) Disconnect the accelerator cable. (b) Disconnect the throttle position sensor connector. (c) Disconnect the throttle control motor connector. (d) Disconnect the accelerator pedal position sensor connector. (e) Disconnect the engine wire clamp from the clamp bracket of the throttle body.

(f) Remove the 2 bolts and nut holding the throttle body to the intake air connector. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf) (g) Remove the 4 nuts and the throttle body bracket. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)

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(h) Disconnect the water bypass hose from the hose clamp on the oil filter bracket. Slide (i) Slightly slide the throttle body away from the intake air Disconnect connector.

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4. REMOVE THROTTLE BODY GASKET Remove the 3 bolts and throttle body gasket. Torque: 21 N·m (210 kgf·cm, 15 ft·lbf)

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2005 LEXUS IS300 (RM1140U)

Author: Date: 1513 IG-8 IGNITION - IGNITION COIL 5. REMOVE IGNITION COILS AND HIGH- TENSION CORDS SET ASSEMBLY (a) Disconnect the 3 connectors from the ignition coils. (b) Remove the 2 bolts, and disconnect the clamps from the engine wire.

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6. REMOVE IGNITION COILS FROM HIGH- TENSION CORD SET

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2005 LEXUS IS300 (RM1140U)

Author: Date: 1514 IG-9 IGNITION - IGNITION COIL

IG00X-04 INSTALLATION Installation is in the reverse order of removal (See page IG-7 ).

2005 LEXUS IS300 (RM1140U)

Author: Date: 1515 IG-10 IGNITION - CAMSHAFT POSITION SENSOR CAMSHAFT POSITION SENSOR IG05V-08 COMPONENTS

Accelerator Cable EVAP Hose

z Gasket Air Intake Chamber Noise Filter Connector

PS Air Hose 28 (280, 21)

z Fuel Pressure Pulsation Damper Gasket 42 (420, 31) Air Assist Hose Engine Wire Clamp z Gasket Fuel Inlet Pipe

z Gasket Vacuum Control Valve Set and No. 2 Vacuum Intake Manifold Assembly Pipe x 7 Engine Wire Clamp Oil Filler Cap 28 (280, 21) Manifold Stay Ground Terminal 39.2 (400, 29) Engine Wire Clamp

PS Pump Rear Stay Engine Wire z No. 3 Timing Belt Cover Water Bypass Hose O-Ring

21 (210, 15) Oil Dipstick and Guide for A/T Throttle Position z O-Ring Sensor Connector Oil Dipstick and Guide for Engine

21 (210, 15) Camshaft Position Sensor Connector

9.0 (90, 80 in.·lbf)

Camshaft Position Sensor

Knock Sensor 2 Connector Starter Connector N·m (kgf·cm, ft·lbf) :Specified torque z Non-reusable part B11949

2005 LEXUS IS300 (RM1140U)

Author: Date: 1516 IG-1 1 IGNITION - CAMSHAFT POSITION SENSOR

IG05W-06 REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE OIL DIPSTICK AND GUIDE FOR ENGINE (See page LU-6 ) 3. REMOVE OIL DIPSTICK AND GUIDE FOR A/T (See page EM-65 ) 4. REMOVE AIR INTAKE CHAMBER (See page SF-46 ) 5. REMOVE VACUUM CONTROL VALVE SET AND NO. 2 VACUUM PIPE (See page EM-34 ) 6. REMOVE NO. 3 TIMING BELT COVER 7. DISCONNECT HOSES AND ENGINE WIRE (a) Disconnect the air assist hose from the intake manifold. (b) Disconnect the water bypass hose (from the water outlet) from the throttle body. (c) Disconnect the 2 ground terminals from the intake manifold. HINT: At time of the installation, tighten so that each calking part should inside. (d) Disconnect the throttle position sensor connector. (e) Disconnect the 6 injector connectors. (f) Disconnect the camshaft position sensor connector. (g) Disconnect the knock sensor 2 connector. (h) Disconnect the starter connector. (i) Disconnect the engine wire clamp from the clamp bracket on the intake manifold. (j) Remove the 3 nuts, and disconnect the engine wire pro- tector from the intake manifold. 8. REMOVE FUEL PRESSURE PULSATION DAMPER (See page SF-26 ) 9. REMOVE PS PUMP REAR STAY Torque: 39.2 N·m (400 kgf·cm, 29 ft·lbf) 10. REMOVE INTAKE MANIFOLD ASSEMBLY (See page EM-34 )

11. REMOVE CAMSHAFT POSITION SENSOR Remove the 2 bolts and sensor. Torque: 9.0 N·m (90 kgf·cm, 80 in.·lbf)

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2005 LEXUS IS300 (RM1140U)

Author: Date: 1517 IG-12 IGNITION - CAMSHAFT POSITION SENSOR

IG05X-03 INSTALLATION Installation is in the reverse order of removal (See page IG-1 1).

2005 LEXUS IS300 (RM1140U)

Author: Date: 1518 IG-13 IGNITION - CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR IG060-09 COMPONENTS Engine Cover

Connector Bracket

Crankshaft Position Sensor Connector Generator Wire Engine Wire Clamp

Pipe Clamp 9.0 (90, 80 in.·lbf) Drive Belt Crankshaft Position Sensor 9.0 (90, 80 in.·lbf)

Generator A/T Oil Cooler Pipe

Pipe Bracket Drive Belt Tensioner Absorber

20 (200, 14)

Engine Under Cover

x 18

N·m (kgf·cm, ft·lbf) : Specified torque B15231

2005 LEXUS IS300 (RM1140U)

Author: Date: 1519 IG-14 IGNITION - CRANKSHAFT POSITION SENSOR

IG05Y-08 REMOVAL 1. REMOVE GENERATOR (See page CH-6 ) 2. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR (a) Disconnect the sensor connector.

(b) Remove the bolt holding the connector bracket to the water pump. 3. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the bolt and sensor. Torque: 9.0 N·m (90 kgf·cm, 80 in.·lbf) (b) Remove the connector bracket from the connector.

B01984

2005 LEXUS IS300 (RM1140U)

Author: Date: 1520 IG-15 IGNITION - CRANKSHAFT POSITION SENSOR

IG05Z-04 INSTALLATION Installation is in the reverse order of removal (See page IG-14 ).

2005 LEXUS IS300 (RM1140U)

Author: Date: 1521