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
Click here .gif)
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
Click here
5. INSTALL WATER OUTLET
Click here
6. INSTALL VALVE STEM CAP
Click here
7. INSTALL VALVE LASH ADJUSTER ASSEMBLY
Click here
8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
Click here
9. INSTALL NO. 1 CHAIN VIBRATION DAMPER
Click here
10. INSTALL NO. 2 CHAIN VIBRATION DAMPER
Click here
11. INSTALL SENSOR WIRE
Click here
12. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY
Click here
13. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY
Click here
14. INSTALL CAMSHAFT BEARING CAP (for Bank 2)
Click here
15. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)
Click here
16. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)
Click here
17. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)
Click here
18. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
Click here
19. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)
Click here
20. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)
Click here
21. INSTALL CAMSHAFT
Click here
22. INSTALL NO. 2 CAMSHAFT
Click here
23. INSTALL CAMSHAFT BEARING CAP (for Bank 1)
Click here
24. SET CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)
Click here
25. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)
Click here
26. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)
Click here
27. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
Click here
28. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)
Click here
29. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)
Click here
30. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
Click here
31. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
Click here
32. INSTALL CHAIN SUB-ASSEMBLY
Click here
33. INSTALL CHAIN TENSIONER SLIPPER
Click here
34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
Click here
35. INSPECT VALVE TIMING
Click here
36. INSTALL TIMING CHAIN COVER ASSEMBLY
Click here
37. INSTALL TIMING CHAIN CASE OIL SEAL
Click here
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:
|
|
(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
Click here
40. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
Click here
41. INSTALL SPARK PLUG TUBE GASKET
Click here
42. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
Click here
43. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Click here
44. INSTALL SENSOR WIRE
Click here
45. INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR
Click here
46. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)
Click here
47. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)
Click here
48. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)
Click here
49. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)
Click here
50. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY
Click here
51. CONNECT WATER BY-PASS HOSE
Click here
52. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
Click here
53. INSTALL CRANKSHAFT PULLEY
Click here
54. INSTALL WATER FILLER BRACKET
Click here
55. INSTALL WIRE HARNESS CLAMP BRACKET
Click here
56. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
Click here
57. INSTALL WATER PUMP PULLEY
Click here
58. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
Click here
59. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
Click here
60. INSTALL COMPRESSOR ASSEMBLY WITH MAGNETIC CLUTCH
Click here
61. INSTALL GENERATOR ASSEMBLY
Click here
62. INSTALL V-RIBBED BELT
Click here
63. INSTALL VACUUM PUMP ASSEMBLY
-
for TMMK Made:
Click here
-
for TMC Made:
Click here
64. INSTALL IGNITION COIL ASSEMBLY
Click here
65. INSTALL KNOCK CONTROL SENSOR
Click here
66. INSTALL ENGINE HANGERS
Click here
67. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND
Click here
READ NEXT:
Drive Belt
PrecautionPRECAUTION NOTICE:
Do not apply or add any oil or grease to the belt tensioner to prevent abnormal noises from the belt tensioner pulley, belt squealing, etc.
Do not allow oil or
On-vehicle Inspection
ON-VEHICLE INSPECTION CAUTION / NOTICE / HINT CAUTION: To prevent injury due to contact with an operating V-ribbed belt or cooling fan, keep your hands and clothing away from the V-ribbed belt and co
SEE MORE:
Installation
INSTALLATION PROCEDURE 1. INSTALL TRANSMISSION OIL COOLER (a) Temporarily install the transmission oil cooler to the automatic transaxle case sub-assembly with the bolt (A). (b) Install the bolt (B). Torque: 13.5 N·m {138 kgf·cm, 10 ft·lbf} (c) Install the bolt (C). Torque: 13.5
Hybrid/EV Battery Control System Circuit Voltage Below Threshold (P300016)
DESCRIPTION The battery ECU assembly alerts the driver and performs fail-safe control based on malfunction signals. If the HV battery is discharged excessively or the hybrid battery system is malfunctioning, this DTC will be stored. HINT: If the HV battery voltage has dropped due to a malfunction in
