Lexus ES: Installation

INSTALLATION

PROCEDURE

1. INSTALL STUD BOLT

HINT:

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

(a) Using an E8 "TORX" socket wrench, install the 2 stud bolts to the intake manifold. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

2. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

(a) Install 2 new No. 1 intake manifold to head gaskets to each cylinder head sub-assembly.

3. INSTALL INTAKE MANIFOLD

(a) Temporarily install the intake manifold to the cylinder head sub-assembly with the 4 bolts and 4 nuts.

(b) Tighten the 4 bolts and 4 nuts in the order shown in the illustration.

	Bolt
	Nut

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

4. INSTALL INJECTOR VIBRATION INSULATOR

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5. INSTALL NO. 1 DELIVERY PIPE SPACER

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6. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY

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7. CONNECT FUEL TUBE SUB-ASSEMBLY

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8. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the No. 2 engine mounting stay RH to the intake manifold and front No. 1 engine mounting bracket LH with the bolt. Torque: 21 N·m {214 kgf·cm, 15 ft·lbf}

(b) Install the No. 2 engine mounting stay RH to the engine mounting insulator sub-assembly RH with the bolt and 2 nuts.

	Bolt
	Nut

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

(c) Connect the wire harness clamp bracket to the No. 2 engine mounting stay RH with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) Engage the wire harness clamp and connect the engine wire.

(e) Install the 2 bolts.

Torque:

Bolt A :

10 N·m {102 kgf·cm, 7 ft·lbf}

Bolt B :

20 N·m {204 kgf·cm, 15 ft·lbf}

9. INSTALL NO. 1 V-BANK COVER BRACKET

HINT:

Perform this procedure only when replacement of the No. 1 V-bank cover bracket is necessary.

(a) Install the 2 No. 1 V-bank cover brackets to the intake air surge tank assembly.

Torque:

9.0 N·m {92 kgf·cm, 80 in·lbf}

10. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET

(a) Install a new air surge tank to intake manifold gasket to the intake air surge tank assembly.

11. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

NOTICE:

Do not apply oil to the bolts and nuts as listed below:

(a) Install the plug to the intake air surge tank assembly.

(b) Temporarily install the intake air surge tank assembly to the intake manifold with the 5 bolts and 2 nuts.

(c) Temporarily install the No. 2 surge tank stay to the intake air surge tank assembly and camshaft housing RH with the 2 bolts.

(d) Tighten the 5 bolts and 2 nuts in the order shown in the illustration.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

	Bolt
	Nut

(e) Tighten the 2 bolts in the order shown in the illustration. Torque: 21 N·m {214 kgf·cm, 15 ft·lbf}

(f) Engage the clamp to connect the No. 2 air tube to the intake air surge tank assembly.

*1 Vacuum Hose Sub-assembly *2 Vacuum Hose *3 No. 2 Air Tube

(g) Engage the clamp to connect the vacuum hose to the intake air surge tank assembly.

(h) Engage the 2 clamps to connect the vacuum hose sub-assembly to the intake air surge tank assembly.

(i) Engage the 2 clamps to connect the vacuum hose sub-assembly to the intake air surge tank assembly.

(j) Connect the vacuum hose sub-assembly to the vacuum switching valve (for ACIS).

(k) Connect the vacuum switching valve (for ACIS) connector.

12. CONNECT PURGE VALVE (PURGE VSV)

(a) Connect the purge valve (purge VSV) to the intake air surge tank assembly with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(b) Connect the No. 1 fuel vapor feed hose to the intake air surge tank assembly.

13. CONNECT VENTILATION HOSE

(a) Connect the ventilation hose to the intake air surge tank assembly and slide the clip to secure it.

14. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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15. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

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16. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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18. INSPECT FOR FUEL LEAK

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19. INSTALL V-BANK COVER SUB-ASSEMBLY

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