Lexus ES: Installation

INSTALLATION

PROCEDURE

1. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

(a) Confirm that the timing mark (cutout) on the crankshaft pulley is aligned with the "0" timing mark of the timing chain cover assembly.

*a Timing Mark (Cutout) *b "0" Timing Mark

2. SET CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 2)

HINT:

Perform Inspection After Repair after replacing the camshaft timing gear assembly.

Click here

(a) Align the mark plate (yellow) with the timing mark of the camshaft timing gear assembly as shown in the illustration and install the No. 2 chain sub-assembly to the camshaft timing gear assembly.

*a Timing Mark *b Mark Plate

(b) Install the chain sub-assembly to the camshaft timing gear assembly, and then set the camshaft timing gear assembly to the camshaft housing sub-assembly LH. HINT: Place the chain sub-assembly on the camshaft timing gear assembly but do not engage the teeth of the sprocket and the chain sub-assembly. Be sure to install the camshaft timing gear assembly with the timing mark facing upward.

*a Place on camshaft timing gear assembly

3. SET CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY (for Bank 2)

HINT:

Perform Inspection After Repair after replacing the camshaft timing exhaust gear assembly.

Click here

(a) Align the mark plate (yellow) with the timing mark of the camshaft timing exhaust gear assembly as shown in the illustration and install the No. 2 chain sub-assembly to the camshaft timing exhaust gear assembly.

*a Timing Mark *b Mark Plate

(b) Set the camshaft timing exhaust gear assembly to the camshaft housing sub-assembly LH.

4. SET NO. 3 CHAIN TENSIONER ASSEMBLY

(a) While lifting up the camshaft timing exhaust gear assembly, pass the No. 3 chain tensioner assembly through the No. 2 chain sub-assembly and set it in place. NOTICE: Temporarily set the No. 3 chain tensioner assembly only, do not install the bolt.

5. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY

HINT:

Perform Inspection After Repair after replacing the No. 3 camshaft sub-assembly.

Click here

(a) Clean the camshaft housing sub-assembly LH and No. 3 camshaft sub-assembly journals and apply engine oil to them.

(b) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap

(c) Align the straight pin of the No. 3 camshaft sub-assembly and the pin hole of the camshaft timing gear assembly, and install the No. 3 camshaft sub-assembly to the camshaft timing gear assembly. NOTICE: Be careful not to damage the contact surface of the camshaft timing gear assembly with the straight pin of the No. 3 camshaft sub-assembly.

*a Pin Hole *b Straight Pin

(d) Check that there is no clearance between the camshaft timing gear assembly and No. 3 camshaft sub-assembly flange.

6. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY

HINT:

Perform Inspection After Repair after replacing the No. 4 camshaft sub-assembly.

Click here

(a) Clean the camshaft housing sub-assembly LH and No. 4 camshaft sub-assembly journals and apply engine oil to them.

(b) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap

(c) Align the straight pin of the No. 4 camshaft sub-assembly and the pin hole of the camshaft timing exhaust gear assembly, and install the No. 4 camshaft sub-assembly to the camshaft timing exhaust gear assembly. NOTICE: Be careful not to damage the contact surface of the camshaft timing exhaust gear assembly with the straight pin of the No. 4 camshaft sub-assembly.

*a Pin Hole *b Straight Pin

(d) Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 4 camshaft sub-assembly flange.

7. SET CAMSHAFT BEARING CAP (for Bank 2)

(a) Clean the camshaft bearing caps and apply engine oil to them.

(b) Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration. HINT: To ensure there is sufficient space for installing the No. 3 camshaft bearing cap and No. 4 camshaft bearing cap, slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

(c) Remove the replacement bolts and washers (No. 3 camshaft bearing cap and No. 4 camshaft bearing cap side). NOTICE: Do not remove any of the replacement bolts and washers other than those on the No. 3 camshaft bearing cap and No. 4 camshaft bearing cap side.

*a Replacement Bolt and Washer *b No. 3 Camshaft Bearing Cap *c No. 4 Camshaft Bearing Cap

(d) Temporarily set the No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.

(e) Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration. NOTICE: Securely insert the straight pins of the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly into the pin holes of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

8. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)

(a) Check that there is no clearance between the camshaft timing gear assembly and No. 3 camshaft sub-assembly flange.

(b) Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration.

(c) Use a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly.

*a	Hold
	Turn

(d) Temporarily install the camshaft timing gear bolt to the camshaft timing gear assembly.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

9. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)

(a) Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 4 camshaft sub-assembly flange.

(b) Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration.

(c) Use a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly.

*a	Hold
	Turn

(d) Temporarily install the camshaft timing gear bolt to the camshaft timing exhaust gear assembly.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

10. INSTALL CAMSHAFT BEARING CAP (for Bank 2)

(a) Clean the camshaft bearing caps and apply engine oil to them.

(b) Check the marks and numbers on the camshaft bearing caps, and then remove the replacement bolts and washers in the order shown in the illustration. Immediately after removing the replacement bolts and washers in the location for a camshaft bearing cap, install the camshaft bearing cap with the bolts in the order shown in the illustration.

Torque:

Bolt (A) :

28 N·m {286 kgf·cm, 21 ft·lbf}

Bolt (B) :

16 N·m {163 kgf·cm, 12 ft·lbf}

*a	Replacement Bolt and Washer
*b	Replacement Bolt and Washer Removal
*c	Part Installation
	Bolt (A)
	Bolt (B)

(c) Check the torque of each bolt again.

11. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)

(a) Use a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly.

*a	Hold
	Turn

(b) Tighten the camshaft timing gear bolt.

Torque:

95 N·m {969 kgf·cm, 70 ft·lbf}

NOTICE:

Be careful not to damage the No. 3 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.

12. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)

(a) Use a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly.

*a	Hold
	Turn

(b) Tighten the camshaft timing gear bolt.

Torque:

95 N·m {969 kgf·cm, 70 ft·lbf}

NOTICE:

Be careful not to damage the No. 4 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.

13. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 3 chain tensioner assembly with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

14. CONNECT CHAIN SUB-ASSEMBLY (for Bank 2)

(a) Align the paint marks on the camshaft timing gear assembly and chain sub-assembly and install the chain sub-assembly to the camshaft timing gear assembly. HINT: If the paint marks are not aligned, align them by turning the No. 3 camshaft sub-assembly slightly.

*a Paint Mark

15. SET CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 1)

HINT:

Perform Inspection After Repair after replacing the camshaft timing gear assembly.

Click here

(a) Align the mark plate (yellow) with the timing mark of the camshaft timing gear assembly as shown in the illustration and install the No. 2 chain sub-assembly to the camshaft timing gear assembly.

*a Timing Mark *b Mark Plate

(b) Install the chain sub-assembly to the camshaft timing gear assembly, and then set the camshaft timing gear assembly to the camshaft housing sub-assembly. HINT: Place the chain sub-assembly on the camshaft timing gear assembly but do not engage the teeth of the sprocket and the chain sub-assembly. Be sure to install the camshaft timing gear assembly with the timing mark facing upward.

*a Place on camshaft timing gear assembly

16. SET CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY (for Bank 1)

HINT:

Perform Inspection After Repair after replacing the camshaft timing exhaust gear assembly.

Click here

(a) Align the mark plate (yellow) with the timing mark of the camshaft timing exhaust gear assembly as shown in the illustration and install the No. 2 chain sub-assembly to the camshaft timing exhaust gear assembly.

*a Timing Mark *b Mark Plate

(b) Set the camshaft timing exhaust gear assembly to the camshaft housing sub-assembly.

17. SET NO. 2 CHAIN TENSIONER ASSEMBLY

(a) While lifting up the camshaft timing exhaust gear assembly, pass the No. 2 chain tensioner assembly through the No. 2 chain sub-assembly and set it in place. NOTICE: Temporarily set the No. 2 chain tensioner assembly only, do not install the bolt.

18. INSTALL CAMSHAFT

HINT:

Perform Inspection After Repair after replacing the camshaft.

Click here

(a) Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain sub-assembly can be installed easily. HINT: When turning the crankshaft, engine oil may spray out of the oil holes.

*a 5 to 10°

(b) Clean the camshaft housing sub-assembly and camshaft journals and apply engine oil to them.

(c) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap

(d) Align the straight pin of the camshaft and the pin hole of the camshaft timing gear assembly, and install the camshaft to the camshaft timing gear assembly. NOTICE: Be careful not to damage the contact surface of the camshaft timing gear assembly with the straight pin of the camshaft.

*a Pin Hole *b Straight Pin

(e) Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

19. INSTALL NO. 2 CAMSHAFT

HINT:

Perform Inspection After Repair after replacing the No. 2 camshaft.

Click here

(a) Clean the camshaft housing sub-assembly and No. 2 camshaft journals and apply engine oil to them.

(b) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration.

*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem *4 Valve Stem Cap

(c) Align the straight pin of the No. 2 camshaft and the pin hole of the camshaft timing exhaust gear assembly, and install the No. 2 camshaft to the camshaft timing exhaust gear assembly. NOTICE: Be careful not to damage the contact surface of the camshaft timing exhaust gear assembly with the straight pin of the No. 2 camshaft.

*a Pin Hole *b Straight Pin

(d) Check that there is no clearance between the camshaft timing gear assembly and No. 2 camshaft flange.

20. SET CAMSHAFT BEARING CAP (for Bank 1)

(a) Clean the camshaft bearing caps and apply engine oil to them.

(b) Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration. HINT: To ensure there is sufficient space for installing the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap, slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

(c) Remove the replacement bolts and washers (No. 1 camshaft bearing cap and No. 2 camshaft bearing cap side). NOTICE: Do not remove any of the replacement bolts and washers other than those on the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap side.

*a Replacement Bolt and Washer *b No. 1 Camshaft Bearing Cap *c No. 2 Camshaft Bearing Cap

(d) Temporarily set the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap.

(e) Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration. NOTICE: Securely insert the straight pins of the camshaft and No. 2 camshaft into the pin holes of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

21. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)

(a) Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

(b) Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration.

(c) Use a wrench to hold the hexagonal portion of the camshaft.

*a	Hold
	Turn

(d) Temporarily install the camshaft timing gear bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

22. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)

(a) Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.

(b) Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration.

(c) Use a wrench to hold the hexagonal portion of the No. 2 camshaft.

*a	Hold
	Turn

(d) Temporarily install the camshaft timing gear bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

23. INSTALL CAMSHAFT BEARING CAP (for Bank 1)

(a) Clean the camshaft bearing caps and apply engine oil to them.

(b) Check the marks and numbers on the camshaft bearing caps, and then remove the replacement bolts and washers in the order shown in the illustration. Immediately after removing the replacement bolts and washers in the location for a camshaft bearing cap, install the camshaft bearing cap with the bolts in the order shown in the illustration.

Torque:

Bolt (A) :

28 N·m {286 kgf·cm, 21 ft·lbf}

Bolt (B), (C) :

16 N·m {163 kgf·cm, 12 ft·lbf}

*a	Replacement Bolt and Washer
*b	Replacement Bolt and Washer Removal
*c	Part Installation
	Bolt (A)
	Bolt (B)
	Bolt (C)

(c) Check the torque of each bolt again.

24. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)

(a) Use a wrench to hold the hexagonal portion of the camshaft.

*a	Hold
	Turn

(b) Tighten the camshaft timing gear bolt.

Torque:

95 N·m {969 kgf·cm, 70 ft·lbf}

NOTICE:

Be careful not to damage the camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.

25. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)

(a) Use a wrench to hold the hexagonal portion of the No. 2 camshaft.

*a	Hold
	Turn

(b) Tighten the camshaft timing gear bolt.

Torque:

95 N·m {969 kgf·cm, 70 ft·lbf}

NOTICE:

Be careful not to damage the No. 2 camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.

26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Install the No. 2 chain tensioner assembly with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

27. CONNECT CHAIN SUB-ASSEMBLY (for Bank 1)

(a) Align the paint marks on the camshaft timing gear assembly and chain sub-assembly and install the chain sub-assembly to the camshaft timing gear assembly. HINT: If the paint marks are not aligned, align them by turning the camshaft slightly.

*a Paint Mark

28. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Turn the crankshaft counterclockwise 30° past the "0" timing mark, and then turn it clockwise to align the notch with the "0" timing mark.

(b) Turn the crankshaft slightly to eliminate the slack in the chain sub-assembly.

HINT:

Make sure there is some slack in the chain sub-assembly around the area where the No. 1 chain tensioner assembly is installed.

(c) Turn the stopper plate clockwise to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

*a Stopper Plate *b Plunger

(d) Turn the stopper plate counterclockwise to set the lock, and insert a 1.0 mm (0.0394 in.) diameter pin into the hole of the stopper plate.

(e) Install the No. 1 chain tensioner assembly to the cylinder head sub-assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(f) Remove the 1.0 mm (0.0394 in.) diameter pin from the No. 1 chain tensioner assembly.

29. INSPECT VALVE TIMING

(a) Check the camshaft timing marks.

(b) Check that each camshaft timing mark is positioned as shown in the illustration.

HINT:

For the camshaft or No. 3 camshaft sub-assembly:

Be sure to check mark (A) at the point where marks (B), (C) and (D) are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

(c) If the valve timing is misaligned, reinstall the chain sub-assembly.

(d) Turn the crankshaft 2 revolutions, set the No. 1 cylinder to TDC/compression and check the timing marks again.

30. INSTALL TIMING CHAIN COVER PLATE

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31. INSTALL SPARK PLUG TUBE GASKET

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32. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

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33. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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34. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)

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35. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)

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36. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)

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37. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)

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38. INSTALL WATER FILLER BRACKET

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39. INSTALL WIRE HARNESS CLAMP BRACKET

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40. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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41. INSTALL VACUUM PUMP ASSEMBLY

42. INSTALL IGNITION COIL ASSEMBLY

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43. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET

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44. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

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45. CONNECT PURGE VALVE (PURGE VSV)

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46. CONNECT VENTILATION HOSE

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47. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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48. INSTALL ENGINE HANGERS

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49. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

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