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

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11. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

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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

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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

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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:

 Installation

INSTALLATION PROCEDURE 1. INSTALL FLOW SHUTTING VALVE (NO. 1 WATER BY-PASS HOSE) (a) Install the flow shutting valve (No. 1 water by-pass hose) with the bolt. Torque: 19 N·m {194 kgf·cm, 14 ft·lbf} (b) Connect the flow shutting valve (No. 1 water by-pass hose) connector. (c) Connect the flow shu

 Replacement

REPLACEMENT CAUTION / NOTICE / HINT The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during input shaft type T oil seal removal/installation are shown below. Necessary Procedure After Parts R

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