Lexus ES: Installation
INSTALLATION
PROCEDURE
1. INSTALL NO. 2 CYLINDER HEAD GASKET
(a) Place a new No. 2 cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
| *a | Lot No. |
.png) | Front of Engine |
NOTICE:
- Remove any oil from the contact surfaces.
- Make sure to install the No. 2 cylinder head gasket in the correct direction.
(b) Apply seal packing to the No. 2 cylinder head gasket as shown in the illustration.
Seal Packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surfaces.
- Install the No. 2 cylinder head gasket within 3 minutes and tighten the cylinder head set bolts within 15 minutes of applying seal packing.
| *1 | No. 2 Cylinder Head Gasket |
| *a | 5.0 to 7.0 mm (0.197 to 0.276 in.) |
| *b | 3.0 to 5.0 mm (0.118 to 0.197 in.) |
| *c | 7.0 to 9.0 mm (0.276 to 0.354 in.) |
| *d | 38.2 mm (1.50 in.) |
| *e | 110.0 mm (4.33 in.) |
| | Front of Engine |
.png) | Seal Packing |
2. INSTALL CYLINDER HEAD LH
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3. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
| *a | Lot No. |
| | Front of Engine |
NOTICE:
- Remove any oil from the contact surfaces.
- Make sure to install the cylinder head gasket in the correct direction.
(b) Apply seal packing to the cylinder head gasket as shown in the illustration.
Seal Packing:
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
NOTICE:
- Remove any oil from the contact surfaces.
- Install the cylinder head gasket within 3 minutes and tighten the cylinder head set bolts within 15 minutes of applying seal packing.
| *1 | Cylinder Head Gasket |
| *a | 5.0 to 7.0 mm (0.197 to 0.276 in.) |
| *b | 3.0 to 5.0 mm (0.118 to 0.197 in.) |
| *c | 7.0 to 9.0 mm (0.276 to 0.354 in.) |
| *d | 38.5 mm (1.52 in.) |
| *e | 144.0 mm (5.67 in.) |
| | Front of Engine |
| | Seal Packing |
4. INSTALL CYLINDER HEAD SUB-ASSEMBLY
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5. INSTALL WATER OUTLET
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6. INSTALL VALVE STEM CAP
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7. INSTALL VALVE LASH ADJUSTER ASSEMBLY
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8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
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9. INSTALL NO. 1 CHAIN VIBRATION DAMPER
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10. INSTALL NO. 2 CHAIN VIBRATION DAMPER
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11. INSTALL SENSOR WIRE
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12. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY
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13. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY
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14. INSTALL CAMSHAFT BEARING CAP (for Bank 2)
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15. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)
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16. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)
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17. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)
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18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
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19. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)
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20. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)
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21. INSTALL CAMSHAFT
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22. INSTALL NO. 2 CAMSHAFT
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23. INSTALL CAMSHAFT BEARING CAP (for Bank 1)
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24. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)
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25. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)
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26. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)
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27. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
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28. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)
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29. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)
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30. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
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31. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
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32. INSTALL CHAIN SUB-ASSEMBLY
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33. INSTALL CHAIN TENSIONER SLIPPER
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34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
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35. INSPECT VALVE TIMING
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36. INSTALL TIMING CHAIN COVER ASSEMBLY
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37. INSTALL TIMING CHAIN CASE OIL SEAL
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38. INSTALL OIL PAN SUB-ASSEMBLY
(a) Install 2 new oil pan gaskets to the timing chain cover assembly.
| (b) Apply seal packing in a continuous line as shown in the illustration. Seal Packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent Seal Packing Diameter: 3.0 to 4.0 mm (0.118 to 0.157 in.) NOTICE:
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(c) Install the oil pan sub-assembly with the 16 bolts and 2 nuts in the order shown in the illustration.
| *a | Torque | *b | Bolt and Nut Tightening Order |
| | Bolt | .png) | Nut |
Torque:
Bolt (A) :
10 N·m {102 kgf·cm, 7 ft·lbf}
Bolt (B), (C), (D) :
21 N·m {214 kgf·cm, 15 ft·lbf}
Nut :
21 N·m {214 kgf·cm, 15 ft·lbf}
Bolt Length:
| Item | Length |
|---|---|
| Bolt (A) | 16 mm (0.630 in.) |
| Bolt (B) | 45 mm (1.77 in.) |
| Bolt (C) | 25 mm (0.984 in.) |
| Bolt (D) | 70 mm (2.76 in.) |
(d) Wipe off any excess seal packing with a clean piece of cloth.
NOTICE:
Do not allow seal packing to contact the No. 1 crankshaft position sensor plate.
| | Wipe off the Seal Packing |
39. INSTALL OIL STRAINER SUB-ASSEMBLY
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40. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
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41. INSTALL SPARK PLUG TUBE GASKET
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42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
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43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
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44. INSTALL SENSOR WIRE
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45. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR
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46. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)
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47. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)
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48. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)
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49. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)
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50. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY
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51. CONNECT WATER BY-PASS HOSE
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52. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
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53. INSTALL CRANKSHAFT PULLEY
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54. INSTALL WATER FILLER BRACKET
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55. INSTALL WIRE HARNESS CLAMP BRACKET
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56. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
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57. INSTALL WATER PUMP PULLEY
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58. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
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59. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
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60. INSTALL COMPRESSOR ASSEMBLY WITH MAGNETIC CLUTCH
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61. INSTALL GENERATOR ASSEMBLY
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62. INSTALL V-RIBBED BELT
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63. INSTALL VACUUM PUMP ASSEMBLY
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for TMMK Made:
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for TMC Made:
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64. INSTALL IGNITION COIL ASSEMBLY
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65. INSTALL KNOCK CONTROL SENSOR
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66. INSTALL ENGINE HANGERS
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67. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND
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READ NEXT:
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