Lexus ES: Installation

INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. INSTALL CAMSHAFT

HINT:

Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly and camshaft timing exhaust gear assembly.

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(a) Turn the crankshaft clockwise to align the timing mark (cutout) on the crankshaft pulley assembly with the "0" timing mark on the No. 2 timing chain cover assembly.

*a "0" Timing Mark *b Timing Mark

(b) Check that the No. 1 valve rocker arm sub-assembly is correctly installed as shown in the illustration.

*1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly *3 Valve Stem Cap

(c) Clean the camshaft housing sub-assembly and the cams and journals of the camshaft and No. 2 camshaft, and then apply engine oil to them.

(d) Apply a light coat of engine oil to the journals of the camshaft and install the camshaft to the camshaft housing sub-assembly.

(e) Apply a light coat of engine oil to the journals of the No. 2 camshaft and install the No. 2 camshaft to the camshaft housing sub-assembly.

(f) Set the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap as shown in the illustration.

*1 No. 1 Camshaft Bearing Cap *2 No. 2 Camshaft Bearing Cap *3 No. 3 Camshaft Bearing Cap *4 No. 4 Camshaft Bearing Cap

(g) Uniformly tighten the 14 bolts in the order shown in the illustration.

Torque:

28.5 N·m {291 kgf·cm, 21 ft·lbf}

(h) Uniformly tighten the 8 bolts in the order shown in the illustration. Torque: 16 N·m {163 kgf·cm, 12 ft·lbf}

(i) Set the camshaft timing gear assembly and camshaft timing exhaust gear assembly to the chain sub-assembly as shown in the illustration.

(j) Align the timing mark on the camshaft timing gear assembly with the paint mark on the chain sub-assembly.

*a Paint Mark *b Timing Mark

(k) Align the timing mark on the camshaft timing exhaust gear assembly with the paint mark on the chain sub-assembly.

*a Paint Mark *b Timing Mark

(l) Using the hexagonal portion of the camshaft, install the camshaft timing gear assembly to the camshaft. NOTICE: Do not damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube.

*a Knock Pin

(m) Check that the knock pin matches the pin hole from the No. 2 timing chain cover sub-assembly side.

(n) Using a 10 mm bi-hexagon socket wrench, temporarily install the camshaft timing gear assembly with the bolt.

HINT:

Temporarily install the bolt enough that the camshaft timing gear assembly does not detach from the knock pin of the camshaft.

(o) Using the hexagonal portion of the No. 2 camshaft, install the camshaft timing exhaust gear assembly to the No. 2 camshaft. NOTICE: Do not damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube.

(p) Temporarily install the 2 bolts.

HINT:

The 2 bolts can only be installed as shown in the illustration if the knock pin on the No. 2 camshaft and the pin hole on the camshaft timing exhaust gear assembly match. If the 2 bolts cannot be installed, the knock pin and pin hole do not match.

(q) Check the status of the camshaft timing gear assembly and camshaft timing exhaust gear assembly temporarily installed to each camshaft.

(1) Camshaft timing gear assembly side:

Check that the chain sub-assembly does not overlap the No. 1 chain vibration damper as shown in the illustration.

NOTICE:

If the chain sub-assembly overlaps the No. 1 chain vibration damper, install it again.

(2) Camshaft timing exhaust gear assembly side: Check that the chain sub-assembly does not overlap the chain tensioner slipper as shown in the illustration. NOTICE: If the chain sub-assembly overlaps the chain tensioner slipper, install it again.

*1 Chain Tensioner Slipper

(r) Using the hexagonal portion of the camshaft, hold the camshaft. NOTICE: Do not damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube. Do not disassemble the camshaft timing gear assembly.

*a Hold

(s) Using a 10 mm bi-hexagon socket wrench, tighten the bolt on the camshaft timing gear assembly.

Torque:

86 N·m {877 kgf·cm, 63 ft·lbf}

(t) Using the hexagonal portion of the No. 2 camshaft, hold the No. 2 camshaft. NOTICE: Do not damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube.

*a Hold

(u) Using a 5 mm hexagon wrench, tighten the 2 bolts.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

(v) Check that the paint marks and timing marks are positioned as shown in the illustration.

*a Paint Mark *b Timing Mark

(w) Using the hexagonal portion of the camshaft, check that the chain sub-assembly slackens when the camshaft is moved in the direction shown in the illustration.

*a	Hold	-	-
	Turn	-	-

NOTICE:

If the chain sub-assembly remains tight and does not slacken, the chain tensioner slipper and No. 1 chain vibration damper may overlap the chain sub-assembly, so install them again.

(x) Remove the pin from the No. 1 chain tensioner assembly.

2. INSTALL STRAIGHT SCREW PLUG

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3. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

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4. INSTALL FUEL PUMP LIFTER GUIDE

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5. INSTALL SPARK PLUG TUBE GASKET

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6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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7. INSTALL VACUUM PUMP ASSEMBLY

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8. INSTALL CAM TIMING CONTROL MOTOR O-RING

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9. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

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10. INSTALL CAMSHAFT TIMING VALVE ASSEMBLY

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11. INSTALL O-RING

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12. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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13. INSTALL NO. 2 ENGINE COVER

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14. INSTALL NO. 3 BRAKE TUBE CLAMP

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15. INSTALL IGNITION COIL ASSEMBLY

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16. CONNECT ENGINE WIRE

(a) Engage the 3 clamps to connect the engine wire.

(b) Engage the 6 connectors.

17. CONNECT AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY

(a) Engage the 2 clamps to connect the air conditioning tube and accessory assembly.

18. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

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