Lexus ES: Installation

INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with hybrid vehicle transaxle assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

PROCEDURE

1. INSTALL AUTOMATIC TRANSMISSION CASE COVER

(a) Install the automatic transmission case cover to the hybrid vehicle transaxle assembly with the clip.

(b) Install the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

2. INSTALL STUD BOLT

(a) Using a E8 "TORX" socket wrench, install the 2 stud bolts to the hybrid vehicle transaxle assembly.

Torque:

30 N·m {306 kgf·cm, 22 ft·lbf}

3. INSTALL TRANSAXLE HOUSING PLUG

(a) Install the transaxle housing plug and a new gasket to the hybrid vehicle transaxle assembly.

Torque:

39.2 N·m {400 kgf·cm, 29 ft·lbf}

4. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the 4 wire harness clamp brackets to the hybrid vehicle transaxle assembly with the 4 bolts.

Torque:

Bolt (A) :

20 N·m {204 kgf·cm, 15 ft·lbf}

Bolt (B) :

30 N·m {306 kgf·cm, 22 ft·lbf}

5. INSTALL TRANSMISSION WIRE

(a) Install the transmission wire to the hybrid vehicle transaxle assembly with the bolt.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

(b) Connect the connector.

6. INSTALL HOSE BRACKET

(a) Temporarily install the hose bracket to the hybrid vehicle transaxle assembly with the 2 bolts.

(b) Tighten the 2 bolts in the order shown in the illustration.

Torque:

11.5 N·m {117 kgf·cm, 8 ft·lbf}

7. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

(a) Install the No. 1 transmission control cable bracket to the hybrid vehicle transaxle assembly with the 2 bolts.

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

8. INSTALL MOTOR COOLING COOLER

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9. INSTALL MOTOR CABLE

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10. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY

(a) Make sure that the knock pins are installed to the engine assembly.

*1 Knock Pin

(b) Align the knock pins with the holes in the hybrid transaxle assembly and, while keeping the contact surfaces of the engine assembly and hybrid vehicle transaxle assembly in close contact with one another, temporarily install the bolt (A). NOTICE: When tightening the bolts, be sure that the contact surfaces of the engine assembly and hybrid vehicle transaxle assembly are in close contact with one another. Do not apply grease to the inner splines of the transmission input damper assembly or input shaft assembly. Make sure that the wire harness or similar items are not pinched between the contact surfaces. Do not use excessive force when installing the hybrid vehicle transaxle assembly. Make sure to align the hybrid vehicle transaxle assembly so that the input shaft assembly of the hybrid vehicle transaxle assembly will be inserted straight into the inner splines of the transmission input damper assembly. When inserting the input shaft assembly of the hybrid vehicle transaxle assembly into the inner splines of the transmission input damper assembly, do not shake the hybrid vehicle transaxle assembly excessively. When installing the hybrid vehicle transaxle assembly to the engine assembly, make sure to securely fit the knock pins into the knock pin holes.

(c) While keeping the contact surfaces of the engine assembly and hybrid vehicle transaxle assembly in close contact with one another, install the 8 bolts. Bolt Bolt Length Torque (A), (B) 50 mm (1.97 in.) 64 N*m (653 kgf*cm, 47 ft.*lbf) (C) 45 mm (1.77 in.) 46 N*m (469 kgf*cm, 34 ft.*lbf) (D) 35 mm (1.38 in.) 25 N*m (255 kgf*cm, 18 ft.*lbf)

11. INSTALL REAR ENGINE MOUNTING BRACKET

(a) Install the rear engine mounting bracket to the hybrid vehicle transaxle assembly with the 4 bolts. Torque: 42 N·m {428 kgf·cm, 31 ft·lbf} HINT: Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (A) → Fully tighten bolt (C)

12. INSTALL REAR ENGINE MOUNTING INSULATOR

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13. INSTALL FRONT ENGINE MOUNTING BRACKET

(a) Install the front engine mounting bracket to the hybrid vehicle transaxle assembly with the 3 bolts. Torque: 42 N·m {428 kgf·cm, 31 ft·lbf} HINT: Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (C) → Fully tighten bolt (A)

14. INSTALL FRONT ENGINE MOUNTING INSULATOR

(a) Install the front engine mounting insulator to the front engine mounting bracket with the bolt.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

15. INSTALL FRONT FRAME ASSEMBLY

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16. INSTALL FLYWHEEL HOUSING SIDE COVER

(a) Install the flywheel housing side cover to the engine assembly.

17. INSTALL STARTER HOLE INSULATOR

(a) Install the starter hole insulator to the engine assembly with the 2 bolts.

Torque:

46 N·m {469 kgf·cm, 34 ft·lbf}

18. CONNECT HV AIR CONDITIONING WIRE

(a) Engage the guide to connect the HV air conditioning wire to the hybrid vehicle transaxle assembly.

(b) Install the bolt.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

19. CONNECT ENGINE WIRE

(a) Install the wire harness to the rack and pinion power steering gear assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Connect the wire harness connector to the rack and pinion power steering gear assembly.

HINT:

Make sure that the connector is fully inserted before rotating the lock lever to engage the lock.

(c) Engage the 5 clamps.

(d) Install the 2 bolts.

Torque:

Bolt (A) :

12.5 N·m {127 kgf·cm, 9 ft·lbf}

Bolt (B) :

10 N·m {102 kgf·cm, 7 ft·lbf}

20. INSTALL STEERING GEAR HEAT INSULATOR

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21. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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22. PERFORM RESOLVER LEARNING

NOTICE:

If the hybrid vehicle transaxle assembly has been replaced, make sure to perform resolver learning.

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