Lexus ES: Installation

INSTALLATION

PROCEDURE

1. INSTALL STUD BOLT

HINT:

If a stud bolt is deformed or its threads are damaged, replace it.

(a) Using an E8 "TORX" socket wrench, install the 2 stud bolts to the exhaust manifold assembly LH (TWC: Front Catalyst). Torque: 19.5 N·m {199 kgf·cm, 14 ft·lbf}

2. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2)

(a) Install a new exhaust manifold to head gasket (for Bank 2) to the cylinder head sub-assembly.

3. INSTALL EXHAUST MANIFOLD ASSEMBLY LH (TWC: Front Catalyst)

(a) Temporarily install the exhaust manifold assembly LH (TWC: Front Catalyst) with the 4 nuts.

(b) Temporarily install the No. 2 manifold stay to the exhaust manifold assembly LH (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut.

(c) Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration. Torque: 21 N·m {214 kgf·cm, 15 ft·lbf}

(d) Tighten the bolt and nut in the order shown in the illustration.

	Bolt
	Nut

Torque:

Nut :

35 N·m {357 kgf·cm, 26 ft·lbf}

Bolt :

34 N·m {347 kgf·cm, 25 ft·lbf}

4. CONNECT NO. 5 WATER BY-PASS HOSE

(a) Engage the 2 clamps to connect the No. 5 water by-pass hose and No. 6 water by-pass hose to the hose clamp.

5. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 2 exhaust manifold heat insulator to the exhaust manifold assembly LH (TWC: Front Catalyst) with the 3 bolts in the order shown in the illustration. Torque: 8.5 N·m {87 kgf·cm, 75 in·lbf}

6. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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7. INSTALL AIR FUEL RATIO SENSOR (for Bank 2)

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8. INSTALL COOL AIR INTAKE DUCT SEAL

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9. INSTALL V-BANK COVER SUB-ASSEMBLY

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10. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1)

(a) Install a new exhaust manifold to head gasket (for Bank 1) to the cylinder head sub-assembly RH.

11. INSTALL EXHAUST MANIFOLD ASSEMBLY RH (TWC: Front Catalyst)

(a) Temporarily install the exhaust manifold assembly RH (TWC: Front Catalyst) with the 4 nuts.

(b) Using a 12 mm deep socket wrench, tighten the 4 nuts in the order shown in the illustration. Torque: 21 N·m {214 kgf·cm, 15 ft·lbf}

12. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 1 exhaust manifold heat insulator to the exhaust manifold assembly RH (TWC: Front Catalyst) with the 3 bolts in the order shown in the illustration. Torque: 8.5 N·m {87 kgf·cm, 75 in·lbf}

*a Temporarily Tighten

13. INSTALL AIR FUEL RATIO SENSOR (for Bank 1)

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14. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

(a) Install 3 new gaskets to the front exhaust pipe assembly (TWC: Rear Catalyst).

(b) Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust pipe support.

(c) Install the front exhaust pipe assembly (TWC: Rear Catalyst) with 4 new bolts and 4 new nuts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

(d) Engage the 2 wire harness clamps.

(e) Connect the 2 heated oxygen sensor connectors.

15. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side)

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16. INSTALL BODY MOUNTING PLATE

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17. INSTALL FRONT FLOOR COVER LH

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18. INSTALL FRONT FLOOR COVER RH

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19. INSPECT FOR EXHAUST GAS LEAK

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20. INSTALL NO. 2 ENGINE UNDER COVER

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21. INSTALL NO. 1 ENGINE UNDER COVER

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22. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

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23. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

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