Lexus ES: Installation

INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

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

PROCEDURE

1. INSTALL REAR NO. 2 ENGINE MOUNTING BRACKET

HINT:

Perform this procedure only when replacement of the rear No. 2 engine mounting bracket or rear engine mounting bracket is necessary.

(a) Install the rear No. 2 engine mounting bracket to the rear engine mounting bracket with the 2 bolts.

Torque:

42 N·m {428 kgf·cm, 31 ft·lbf}

2. INSTALL TORQUE CONVERTER ASSEMBLY

(a) Set the key at the top of the front oil pump drive gear and put a matchmark on the transaxle housing.

*a Matchmark *b Key

(b) Apply MP grease to place a matchmark on the torque converter assembly so that the position of its groove is clearly indicated.

*a	Groove
*b	Matchmark
	MP Grease

(c) Align the matchmark on the transaxle housing with the one on the torque converter assembly and engage the splines of the input shaft with the turbine runner splines. NOTICE: Install the torque converter assembly to the input shaft while keeping it horizontal. Do not damage the front oil pump oil seal.

*1 Front Oil Pump Oil Seal *a Matchmark

(d) Rotate the torque converter assembly approximately 180° and engage the splines of the stator shaft with the stator assembly. NOTICE: Do not push the torque converter assembly excessively when rotating it. Install the torque converter assembly to the input shaft while keeping it horizontal. Do not damage the front oil pump oil seal.

*1 Front Oil Pump Oil Seal *a Matchmark

(e) Rotate the torque converter assembly approximately 180° again, align the matchmark on the torque converter assembly with the one on the housing and insert the groove of the torque converter assembly into the key of the oil pump drive gear. NOTICE: Do not push the torque converter assembly excessively when rotating it. Install the torque converter assembly to the input shaft while keeping it horizontal. Do not damage the front oil pump oil seal.

*1 Front Oil Pump Oil Seal *a Matchmark

(f) Clean the drive plate and torque converter assembly setting bolt holes.

(g) Using a vernier caliper and straightedge, measure the dimension (A) shown in the illustration and check the dimension (A). Standard: 14.3 mm (0.563 in.) or more NOTICE: Make sure to deduct the thickness of the straightedge. If the automatic transaxle assembly is installed to the engine assembly with the torque converter assembly not sufficiently inserted, the torque converter assembly may be damaged. Do not include the thickness of the set block.

3. INSTALL TRANSFER AND TRANSAXLE SETTING STUD BOLT

(a) Clean and degrease the installation holes of the transfer and transaxle setting stud bolt.

(b) Using 2 nuts, install a new transfer and transaxle setting stud bolt to the transaxle housing position shown in the illustration.

*a	53 mm (2.09 in.)
	Sealant

Torque:

39.2 N·m {400 kgf·cm, 29 ft·lbf}

NOTICE:

Install the sealed side of the transfer and transaxle setting stud bolt to the transaxle housing.

(c) Using 2 nuts, install 3 new transfer and transaxle setting stud bolts to the transaxle housing at the positions shown in the illustration.

*a	73 mm (2.87 in.)
	Sealant

Torque:

39.2 N·m {400 kgf·cm, 29 ft·lbf}

NOTICE:

Install the sealed side of the transfer and transaxle setting stud bolt to the transaxle housing.

4. INSTALL TRANSFER ASSEMBLY

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5. INSTALL TRANSMISSION VIBRATION CONTROL RUBBER

(a) Clean the installation surface of the 2 transmission vibration control rubbers of the transmission case side cover.

Area to be cleaned

NOTICE:

Completely remove any oil or grease from the contact surfaces of the transmission case side cover.

(b) Install 2 new transmission vibration control rubbers to the transmission case side cover.

*a	Protrusion (A)
*b	Protrusion (B)
*c	Protrusion (C)
*d	Protrusion (D)
	Installation Position

6. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the 4 wire harness clamp brackets to the automatic transaxle case sub-assembly and transmission case side cover with the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Install the wire harness clamp bracket to the automatic transaxle case sub-assembly with the bolt.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

(c) Install the wire harness clamp bracket to the automatic transaxle case sub-assembly with the bolt.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

7. INSTALL TRANSMISSION CASE PLUG ASSEMBLY

(a) Coat the O-ring of a new transmission case plug assembly with Toyota Genuine ATF WS.

(b) Install the transmission case plug assembly to the transaxle housing.

8. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

(a) Install the No. 1 transmission control cable bracket to the automatic transaxle case sub-assembly with the 2 bolts.

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

9. INSTALL TRANSMISSION OIL COOLER

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10. INSTALL NO. 1 OIL COOLER TUBE SUB-ASSEMBLY WITHOUT HOSE

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11. CONNECT INLET NO. 1 OIL COOLER HOSE

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12. CONNECT OUTLET NO. 1 OIL COOLER HOSE

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13. INSTALL REAR ENGINE MOUNTING BRACKET SUB-ASSEMBLY

(a) Install the rear engine mounting bracket sub-assembly to the transaxle housing 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)

14. INSTALL PROPELLER SHAFT HEAT INSULATOR

(a) Install the propeller shaft heat insulator to the rear No. 2 engine mounting bracket and transfer assembly with the 3 bolts. Torque: 18 N·m {184 kgf·cm, 13 ft·lbf} HINT: Tightening order: Temporarily tighten bolt (A) → Temporarily tighten bolt (B) → Fully tighten bolt (C) → Fully tighten bolt (B) → Fully tighten bolt (A)

15. INSTALL REAR NO. 2 ENGINE MOUNTING INSULATOR

(a) Install the rear No. 2 engine mounting insulator to the automatic transaxle case sub-assembly with the 5 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) → Fully tighten bolt (D)

16. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

(a) Apply clutch spline grease to the surface of the crankshaft that contacts the torque converter assembly centerpiece.

Clutch Spline Grease:

Toyota Genuine Clutch Spline Grease or equivalent

Maximum Grease Amount:

Approximately 1 g (0.0353 oz)

*1	Crankshaft
*2	Torque Converter Assembly Centerpiece
	Clutch Spline Grease

(b) Confirm that the 2 knock pins are installed on the engine assembly and are not damaged.

*1 Knock Pin

(c) While keeping the engine assembly and automatic transaxle assembly horizontal, align the knock pins with the holes in the automatic transaxle assembly and install the automatic transaxle assembly with the 8 bolts shown in the illustration. Torque: Bolt (A) : 64 N·m {653 kgf·cm, 47 ft·lbf} Bolt (B) : 46 N·m {469 kgf·cm, 34 ft·lbf} Bolt (C) : 25 N·m {255 kgf·cm, 18 ft·lbf} Bolt (D) : 46 N·m {469 kgf·cm, 34 ft·lbf} Bolt Length: Bolt Length (A) 50 mm (1.97 in.) (B) 45 mm (1.77 in.) (C) 35 mm (1.38 in.) (D) 45 mm (1.77 in.) NOTICE: Confirm that the knock pins are installed to the automatic transaxle assembly contact surface of the cylinder block sub-assembly before installing the automatic transaxle assembly. Do not forcibly pry on the automatic transaxle assembly. Check that the torque converter assembly rotates.

17. INSTALL STARTER ASSEMBLY

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18. INSTALL FLYWHEEL HOUSING SIDE COVER

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19. INSTALL FRONT ENGINE MOUNTING BRACKET

(a) Install the front engine mounting bracket to the transaxle housing 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)

20. INSTALL FRONT FRAME ASSEMBLY

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21. CONNECT WIRE HARNESS

(a) Engage the wire harness clamp to connect the wire harness to the automatic transaxle assembly.

(b) Install the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(c) Engage the 9 wire harness clamps to connect the wire harness.

(d) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(e) Connect 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}

(f) Connect the rack and pinion power steering gear assembly connector.

NOTICE:

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

(g) Engage the wire harness clamp and connect the vacuum switching valve (for active control engine mount system) connector.

(h) Connect the park/neutral position switch assembly connector.

(i) Connect the transmission wire connector and rotate the lever and engage the claw. HINT: Rotate the lever until the claw of the transmission wire connector makes a click sound.

22. INSTALL STEERING GEAR HEAT INSULATOR

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23. INSTALL BREATHER PLUG HOSE

(a) Install the breather plug sub-assembly to the breather plug hose.

(b) Install the breather plug hose to the No. 1 breather plug (ATM).

(c) Engage the hose clamp to connect the breather plug hose.

24. CONNECT WATER BY-PASS HOSE ASSEMBLY

(a) Connect the water by-pass hose assembly to the transmission oil cooler and slide the clip to secure it.

25. INSTALL FLOW SHUTTING VALVE (NO. 1 WATER BY-PASS HOSE)

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26. CONNECT VACUUM HOSE

(a) Engage the 5 clamps to connect the vacuum hose to the automatic transaxle assembly.

(b) Connect the vacuum hose to the vacuum hose connector.

27. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

(a) Remove any remaining adhesive from the 6 drive plate and torque converter assembly setting bolts.

(b) Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 6 drive plate and torque converter assembly setting bolts. Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent NOTICE: Make sure to install the 6 drive plate and torque converter assembly setting bolts immediately after applying adhesive to prevent foreign matter from attaching to them.

*a Adhesive

(c) Turn the crankshaft to gain access to the installation locations of the 6 drive plate and torque converter assembly setting bolts and install each drive plate and torque converter assembly setting bolt while holding the crankshaft pulley bolt with a wrench.

Torque:

41 N·m {418 kgf·cm, 30 ft·lbf}

NOTICE:

First install the black colored drive plate and torque converter assembly setting bolt, and then the remaining 5 silver colored drive plate and torque converter assembly setting bolts.

28. INSTALL FLYWHEEL HOUSING UNDER COVER

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29. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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30. CHECK AUTOMATIC TRANSAXLE SYSTEM

NOTICE:

If automatic transaxle parts have been replaced, refer to Parts Replacement Compensation Table to determine if any additional operations are necessary.

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