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 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 exhaust manifold heat insulator and No. 1 upper front floor heat insulator.

HINT:

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

(c) Using a 12 mm deep socket wrench, temporarily install the exhaust manifold (TWC: Front Catalyst) to the cylinder head sub-assembly with 7 new nuts.

(d) Using the 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 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 2 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)

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8. INSTALL FRONT CENTER UPPER SUSPENSION BRACE SUB-ASSEMBLY

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9. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

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10. INSTALL FRONT LOWER NO. 1 FLOOR HEAT INSULATOR

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11. 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) Engage the wire harness clamp.

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

12. INSTALL CENTER FLOOR CROSSMEMBER BRACE

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13. INSTALL FRONT CENTER FLOOR BRACE

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14. INSTALL FRONT FLOOR COVER LH

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15. INSTALL FRONT FLOOR COVER RH

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16. INSPECT FOR EXHAUST GAS LEAK

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17. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

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18. INSTALL NO. 1 ENGINE UNDER COVER

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19. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

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20. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

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