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 CYLINDER HEAD GASKET
(a) Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.
(b) Place a new cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
| *a | Lot No. |
.png) | Front of Engine |
NOTICE:
- Make sure that the cylinder head gasket is installed in the correct orientation.
- Remove any oil from the contact surfaces.
2. INSTALL CYLINDER HEAD SUB-ASSEMBLY
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3. INSTALL NO. 2 CAMSHAFT
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4. INSTALL CAMSHAFT
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5. INSTALL CAMSHAFT BEARING CAP
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6. INSTALL VALVE STEM CAP
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7. INSTALL VALVE LASH ADJUSTER ASSEMBLY
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8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
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9. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
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10. INSTALL FUEL PUMP LIFTER GUIDE
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11. INSTALL TIMING CHAIN COVER ASSEMBLY
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12. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
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13. SET NO. 1 CYLINDER TO TDC (COMPRESSION)
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14. INSTALL NO. 1 CHAIN VIBRATION DAMPER
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15. INSTALL CHAIN TENSIONER SLIPPER
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16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
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17. INSTALL CHAIN SUB-ASSEMBLY
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18. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
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19. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY
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20. SET NO. 1 CYLINDER TO TDC (COMPRESSION)
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21. INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY
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22. INSTALL TIMING CHAIN COVER OIL SEAL
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23. INSTALL SPARK PLUG TUBE GASKET
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24. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
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25. INSTALL WATER BY-PASS OUTLET SUB-ASSEMBLY
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26. INSTALL WATER OUTLET
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27. INSTALL CRANKSHAFT PULLEY ASSEMBLY
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28. INSTALL CAM TIMING CONTROL MOTOR O-RING
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29. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY
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30. INSTALL O-RING
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31. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY
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32. INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY
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33. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
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34. INSTALL IGNITION COIL ASSEMBLY
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35. INSTALL DIRECT FUEL INJECTOR ASSEMBLY
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36. INSTALL FUEL DELIVERY PIPE
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37. INSTALL PORT FUEL INJECTOR ASSEMBLY
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38. INSTALL NO. 5 ENGINE WIRE
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39. INSTALL INJECTOR VIBRATION INSULATOR
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40. INSTALL NO. 1 DELIVERY PIPE SPACER
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41. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
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42. INSTALL NO. 7 WATER BY-PASS HOSE
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43. TEMPORARILY INSTALL FUEL PUMP ASSEMBLY (for High Pressure)
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44. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY
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45. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)
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46. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY
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47. CONNECT FUEL TUBE SUB-ASSEMBLY
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48. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET
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49. INSTALL INTAKE MANIFOLD
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50. INSTALL NO. 2 WATER BY-PASS PIPE
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51. INSTALL NO. 3 WATER BY-PASS PIPE
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52. INSTALL EGR VALVE ASSEMBLY
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53. INSTALL NO. 4 WATER BY-PASS HOSE
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54. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY
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55. INSTALL EGR COOLER ASSEMBLY
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56. INSTALL THROTTLE BODY GASKET
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57. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY
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58. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)
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59. INSTALL MANIFOLD STAY
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60. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
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61. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)
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62. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY
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63. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY
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64. INSTALL ENGINE HANGERS
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65. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND
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