Lexus ES manuals

Lexus ES: Installation

INSTALLATION

PROCEDURE

1. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Type A

(1) Install the No. 2 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 6 bolts.

Torque:

11 N·m {112 kgf·cm, 8 ft·lbf}

(b) Type B

(1) Install the No. 2 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 3 bolts.

Torque:

11 N·m {112 kgf·cm, 8 ft·lbf}

2. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

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

(b) Temporarily install the exhaust manifold (TWC: Front Catalyst), No. 1 upper front floor heat insulator and No. 1 exhaust manifold heat insulator.

HINT:

At this time, do not install the parts with bolts or nuts.

(c) Temporarily install the exhaust manifold (TWC: Front Catalyst) to the cylinder head sub-assembly with 7 new nuts.

(d) Using a 12 mm deep socket wrench, tighten the 7 nuts in the order shown in the illustration.

Torque:

26 N·m {265 kgf·cm, 19 ft·lbf}

3. INSTALL MANIFOLD STAY

(a) Temporarily install the manifold stay to the exhaust manifold (TWC: Front Catalyst) and cylinder block sub-assembly with the bolt and nut.

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

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Type A

(1) Using a 10 mm union nut wrench, install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 5 bolts.

Torque:

Specified tightening torque :

10 N·m {102 kgf·cm, 7 ft·lbf}

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

    Click here

  • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 8.8 N*m (90 kgf*cm, 78 in.*lbf)

*a

Torque Wrench Fulcrum Length

(b) Type B

(1) Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

5. INSTALL NO. 1 UPPER FRONT FLOOR HEAT INSULATOR

(a) Using a 10 mm union nut wrench, install the No. 1 upper front floor heat insulator to the vehicle body with the 3 nuts.

Torque:

Specified tightening torque :

4.9 N·m {50 kgf·cm, 43 in·lbf}

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

    Click here

  • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 4.3 N*m (44 kgf*cm, 38 in.*lbf)

*a

Torque Wrench Fulcrum Length

6. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the wire harness clamp bracket with the bolt.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

7. INSTALL AIR FUEL RATIO SENSOR (for Sensor 1)

Click here

8. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

Click here

9. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Click here

10. INSTALL FRONT LOWER NO. 1 FLOOR HEAT INSULATOR

Click here

11. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

Click here

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

(a) Install 2 new gaskets to the front exhaust pipe assembly (TWC: Rear Catalyst).

(b) Connect the front exhaust pipe assembly (TWC: Rear Catalyst) to the 2 exhaust pipe supports.

(c) Install the front exhaust pipe assembly (TWC: Rear Catalyst) to the exhaust manifold (TWC: Front Catalyst) and center exhaust pipe assembly with 2 new bolts and 2 new nuts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

(d) Connect the air fuel ratio sensor (for sensor 2) connector.

(e) Engage the 2 wire harness clamps.

13. INSTALL CENTER FLOOR CROSSMEMBER BRACE

Click here

14. INSTALL FRONT CENTER FLOOR BRACE

Click here

15. INSTALL FRONT FLOOR COVER LH

Click here

16. INSTALL FRONT FLOOR COVER RH

Click here

17. INSPECT FOR EXHAUST GAS LEAK

Click here

18. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

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19. INSTALL NO. 1 ENGINE UNDER COVER

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20. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

Click here

21. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

Click here

READ NEXT:

 Exhaust Pipe

 Components

COMPONENTS ILLUSTRATION *1 FRONT FLOOR COVER LH *2 FRONT FLOOR COVER RH N*m (kgf*cm, ft.*lbf): Specified torque - - ILLUSTRATION *1 CENTER FLOOR CROSSMEMBER BRACE *2

 Removal

REMOVAL CAUTION / NOTICE / HINT The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during fron

SEE MORE:

 Disassembly

DISASSEMBLY PROCEDURE 1. REMOVE OIL PUMP RELIEF VALVE (a) Using a 27 mm socket wrench, remove the oil pump relief valve plug from the oil pump cover sub-assembly. *1 Oil Pump Relief Valve *2 Oil Pump Relief Valve Spring *3 Oil Pump Relief Valve Plug (b) Remove

 Diagnostic Trouble Code Chart

DIAGNOSTIC TROUBLE CODE CHART Power Trunk Lid System DTC No. Detection Item Link B2205 Kick Sensor Circuit B2222 PBD/PTL Pulse Sensor B2225 PBD/PTL Motor Clutch Malfunction B2250 PBD/PTL Closer Operation B2251 PBD/PTL Closer Switch U0

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