Lexus ES: Installation

INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL ENGINE MOUNTING INSULATOR LH

HINT:

Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

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2. INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH

HINT:

Perform this procedure only when replacement of the engine mounting bracket sub-assembly LH is necessary.

(a) Temporarily tighten the bolt (A), and then fully tighten the 4 bolts in the order of (B), (C), (D) and (A). Torque: 72 N·m {734 kgf·cm, 53 ft·lbf} NOTICE: Make sure that there is no gap between the engine mounting bracket sub-assembly LH and vehicle body before tightening the bolts.

3. INSTALL ENGINE MOUNTING SPACER

HINT:

Perform this procedure only when replacement of the engine mounting spacer is necessary.

(a) Install the engine mounting spacer to the vehicle body with the 2 bolts. Torque: 72 N·m {734 kgf·cm, 53 ft·lbf} NOTICE: Temporarily tighten the bolt (A), and then fully tighten the 2 bolts in the order of (B) and (A).

4. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:

Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

(a) Install the engine mounting insulator sub-assembly RH to the engine mounting spacer and vehicle body with the nut and 2 bolts. Torque: 72 N·m {734 kgf·cm, 53 ft·lbf} NOTICE: Temporarily tighten the bolt (A), and then fully tighten the 2 bolts and nut in the order of (B), (A) and (C).

(b) Engage the clamp.

(c) Install the bracket to the engine mounting insulator sub-assembly RH with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(d) Install the radiator reserve tank assembly with the bolt and nut in the order shown in the illustration. Torque: 5.0 N·m {51 kgf·cm, 44 in·lbf}

(e) Engage the clamp.

5. INSTALL ENGINE HANGERS

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6. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

(a) Remove the engine assembly from the engine stand.

7. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

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9. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

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10. INSTALL FRONT ENGINE MOUNTING BRACKET

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11. INSTALL REAR ENGINE MOUNTING INSULATOR

HINT:

Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

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12. INSTALL FRONT ENGINE MOUNTING INSULATOR

HINT:

Perform this procedure only when replacement of the front engine mounting insulator is necessary.

(a) Install the front engine mounting insulator to the front frame assembly with the 3 nuts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

13. INSTALL FRONT FRAME ASSEMBLY

(a) Install the rear engine mounting insulator to the front frame assembly with the 4 nuts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

(b) 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}

14. REMOVE ENGINE HANGERS

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15. INSTALL ENGINE WIRE

(a) Connect all connectors and clamps, and install the engine wire to the engine assembly with transaxle.

16. CONNECT WATER BY-PASS HOSE ASSEMBLY

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17. CONNECT NO. 1 WATER BY-PASS HOSE

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18. INSTALL BREATHER PLUG HOSE

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19. INSTALL STARTER ASSEMBLY

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20. CONNECT VACUUM HOSE

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21. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

HINT:

Perform Inspection After Repair after replacing the engine assembly.

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(a) Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front frame assembly level, set an engine lifter underneath the engine assembly with transaxle and front frame assembly.

(b) Operate the engine lifter and install the engine assembly with transaxle to the vehicle.

CAUTION:

Do not raise the engine assembly with transaxle more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

(c) w/o Suspension Tower Damper:

	Bolt
	Nut

(1) Install the front bumper extension sub-assembly RH and front bumper extension sub-assembly LH to the front frame assembly and vehicle body with the 8 bolts.

Torque:

Bolt (A) :

9.0 N·m {92 kgf·cm, 80 in·lbf}

Bolt (B) :

12.5 N·m {127 kgf·cm, 9 ft·lbf}

Bolt (C) :

135 N·m {1377 kgf·cm, 100 ft·lbf}

(2) Install the front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH to the front frame assembly and vehicle body with the 4 bolts and 2 nuts.

Torque:

Bolt (D) :

17.5 N·m {178 kgf·cm, 13 ft·lbf}

Bolt (E) :

135 N·m {1377 kgf·cm, 100 ft·lbf}

Nut :

17.5 N·m {178 kgf·cm, 13 ft·lbf}

	Bolt
	Nut

(d) w/ Suspension Tower Damper:

(1) Install the front bumper extension sub-assembly RH and front bumper extension sub-assembly LH to the front frame assembly and vehicle body with the 6 bolts.

Torque:

Bolt (A) :

9.0 N·m {92 kgf·cm, 80 in·lbf}

Bolt (B) :

12.5 N·m {127 kgf·cm, 9 ft·lbf}

Bolt (C) :

135 N·m {1377 kgf·cm, 100 ft·lbf}

(2) Install the front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH to the front frame assembly and vehicle body with the 4 bolts and 2 nuts.

Torque:

Bolt (D) :

17.5 N·m {178 kgf·cm, 13 ft·lbf}

Bolt (E) :

135 N·m {1377 kgf·cm, 100 ft·lbf}

Nut :

17.5 N·m {178 kgf·cm, 13 ft·lbf}

(e) Install the engine mounting insulator LH to the engine mounting bracket sub-assembly LH with the bolt and nut.

Torque:

42 N·m {428 kgf·cm, 31 ft·lbf}

(f) Install the engine mounting insulator sub-assembly RH to the front No. 1 engine mounting bracket LH with the 3 bolts and nut.

Torque:

Bolt :

72 N·m {734 kgf·cm, 53 ft·lbf}

Nut :

42 N·m {428 kgf·cm, 31 ft·lbf}

(g) Install the No. 2 engine mounting stay RH with the bolt and 2 nuts.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

22. INSTALL SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper)

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23. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

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24. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

25. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Upper Side)

(a) Install the No. 1 exhaust pipe support bracket to the oil pan sub-assembly with the 2 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

26. INSTALL FRONT DRIVE SHAFT ASSEMBLY

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27. INSTALL EXHAUST MANIFOLD

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28. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

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29. CONNECT EARTH WIRE

(a) Connect the earth wire to the vehicle body with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

30. CONNECT ENGINE WIRE

(a) Engage the clamp and connect the engine wire to the vehicle body.

(b) Connect the engine wire with the bolt.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(c) Engage the 2 clamps.

(d) Engage the claw and connect the engine wire to the engine room relay block and junction block assembly.

(e) Install the nut to the engine room relay block and junction block assembly.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

(f) Connect the 4 connectors to the engine room relay block and junction block assembly.

(g) Install the No. 2 relay block cover to the engine room relay block and junction block assembly.

31. CONNECT SUCTION HOSE

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32. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

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33. CONNECT NO. 1 FUEL HOSE

(a) Install the No. 1 fuel hose with the bolt.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

(b) Connect the No. 1 fuel hose (for Port Injection).

(1) Connect the No. 1 fuel hose to the fuel pipe.

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(c) Connect the No. 1 fuel hose (for Direct Injection).

(1) Connect the No. 1 fuel hose to the fuel pipe.

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(d) Install the No. 1 fuel pipe clamp to the fuel tube connector.

(e) Engage the 2 claws to install the No. 2 fuel pipe clamp.

34. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose to the heater water pipe and slide the clip to secure it.

35. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose to the water outlet and slide the clip to secure it.

(b) Engage the clamp.

36. CONNECT RADIATOR HOSE SUB-ASSEMBLY

(a) Connect the radiator hose sub-assembly to the water outlet and slide the clip to secure it.

(b) Install the radiator hose sub-assembly to the engine assembly with the 2 bolts.

Torque:

8.0 N·m {82 kgf·cm, 71 in·lbf}

37. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.

38. CONNECT UNION TO CHECK VALVE HOSE

(a) Connect the union to check valve hose to the brake booster assembly and slide the clip to secure it.

39. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose to the No. 1 vacuum switching valve and slide the clip to secure it.

40. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

(b) Connect the transmission control cable assembly to the transmission control shaft lever as shown in the illustration. NOTICE: Before installing the transmission control cable assembly, check that the park/neutral position switch assembly and shift lever are in N.

*a Correct *b Incorrect

41. INSTALL BATTERY CLAMP SUB-ASSEMBLY

(a) Install the battery clamp sub-assembly with the 3 bolts.

Torque:

18.5 N·m {189 kgf·cm, 14 ft·lbf}

(b) Engage the 5 clamps to the battery clamp sub-assembly.

42. INSTALL BATTERY

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43. CONNECT ENGINE ROOM MAIN WIRE

(a) Connect the engine wire with engine room main wire to the positive (+) battery terminal with the nut.

Torque:

7.6 N·m {77 kgf·cm, 67 in·lbf}

44. INSTALL ECM

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45. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

(a) Install the air cleaner assembly with air cleaner hose to the throttle body with motor assembly. NOTICE: Align the cutout of the air cleaner hose assembly with the protrusion of the throttle body with motor assembly.

*a Protrusion *b Cutout *c Hose Clamp End *d 2.0 mm (0.0787 in.) *e Paint Mark

(b) Tighten the hose clamp in the position shown in the illustration.

NOTICE:

Make sure that the end of the hose clamp is positioned as shown in the illustration.

(c) Insert the 3 pins of the air cleaner assembly into the 3 air cleaner supports as shown in the illustration. NOTICE: Insert the 3 pins of the air cleaner assembly into the 3 air cleaner supports at the same time. Check that the pins are securely inserted into air cleaner supports.

*a Air Cleaner Support

(d) Engage the vacuum hose to the air cleaner hose.

(e) Engage the 3 wire harness clamps.

(f) Connect the mass air flow meter sub-assembly connector.

(g) Connect the No. 2 ventilation hose to the air cleaner hose and slide the clip to secure it. NOTICE: Make sure that the condition of the clip is as shown in the illustration.

*1 No. 1 Fuel Vapor Feed Hose *2 No. 2 Ventilation Hose *a Top *b Paint Mark *c Rear of Vehicle *d 180° (Claw of Clip Location)

(h) Engage the 2 clamps to connect the No. 1 fuel vapor feed hose to the air cleaner hose.

46. INSTALL INLET AIR CLEANER ASSEMBLY

(a) Install the inlet air cleaner assembly with the 2 bolts in the order shown in the illustration. Torque: 8.0 N·m {82 kgf·cm, 71 in·lbf}

47. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Engage the 4 clips in the order shown in the illustration to install the V-bank cover sub-assembly. NOTICE: Make sure that the clips are engaged securely. Do not subject the clips to shock or apply excessive force to the clips when engaging them or they may be damaged. If the clips are not engaged in the order shown in the illustration, the V-bank cover sub-assembly may be damaged.

48. INSPECT VACUUM HOSES

(a) Inspect the vacuum hoses.

49. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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50. ADD ENGINE OIL

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51. ADD ENGINE COOLANT

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52. ADD AUTOMATIC TRANSAXLE FLUID

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53. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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54. WARM UP ENGINE

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55. INSPECT SHIFT LEVER POSITION

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56. ADJUST SHIFT LEVER POSITION

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57. INSPECT FOR ENGINE OIL LEAK

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58. INSPECT FOR COOLANT LEAK

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59. INSPECT FOR REFRIGERANT LEAK

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60. INSPECT FOR FUEL LEAK

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61. INSPECT FOR EXHAUST GAS LEAK

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62. CHECK ENGINE OIL LEVEL

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63. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK

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64. INSTALL FRONT LOWER BUMPER ABSORBER

(a) Engage the 2 claws to the front lower bumper absorber.

(b) Install the 4 bolts.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

65. INSTALL FRONT BUMPER COVER

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66. INSTALL FRONT FENDER APRON SEAL LH

(a) Install the front fender apron seal LH with the 2 screws and clip.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

67. INSTALL FRONT FENDER APRON SEAL RH

(a) Install the front fender apron seal RH with the 2 screws and clip.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

68. INSTALL NO. 2 ENGINE UNDER COVER

(a) Install the No. 2 engine under cover with the 2 screws and 3 clips.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

69. INSTALL NO. 3 ENGINE UNDER COVER

(a) Install the No. 3 engine under cover with the 2 screws and 3 clips.

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

70. INSTALL NO. 1 ENGINE UNDER COVER

(a) Install the No. 1 engine under cover with the bolt, 6 screws and 2 clips.

Torque:

Bolt :

7.5 N·m {76 kgf·cm, 66 in·lbf}

71. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

(a) Install the front wheel opening extension pad LH with the 3 screws.

72. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

(a) Install the front wheel opening extension pad RH with the 3 screws.

73. INSTALL FRONT WHEELS

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74. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

75. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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76. PERFORM INITIALIZATION

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77. INSPECT IGNITION TIMING

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78. INSPECT ENGINE IDLE SPEED

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79. INSPECT CO/HC

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80. CHECK FOR SPEED SENSOR SIGNAL

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