Lexus ES: Installation

INSTALLATION

PROCEDURE

1. INSTALL HOLE PLUG

(a) Install the 7 hole plugs to the front frame assembly.

HINT:

There are 2 different shapes of hole plug.

2. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION LH

(a) Align a new front suspension member body mounting rear cushion LH as shown in the illustration and set it to the front frame assembly.

*a	View from Underneath
	Front of the Vehicle

(b) Install SST as shown in the illustration. SST: 09570-24011 SST: 09830-10010 09830-01010 09830-01020 09830-01040 09830-01060 NOTICE: Apply molybdenum grease to the threads and tip of the SST center bolt before use.

*1 Front Suspension Member Body Mounting Rear Cushion LH

(c) Using SST, install the front suspension member body mounting rear cushion LH as shown in the illustration.

*a	Hold
	Turn

NOTICE:

Check that there is no clearance between the front frame assembly and the front suspension member body mounting rear cushion LH.

3. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION

(a) Align a new front suspension member body mounting rear cushion as shown in the illustration and set it to the front frame assembly.

*a	View from Underneath
	Front of the Vehicle

(b) Install SST using the same procedure as for the front suspension member body mounting rear cushion LH.

SST: 09570-24011

SST: 09830-10010

09830-01010

09830-01020

09830-01040

09830-01060

NOTICE:

Apply molybdenum grease to the threads and tip of the SST center bolt before use.

(c) Using SST, install the front suspension member body mounting rear cushion.

NOTICE:

Check that there is no clearance between the front frame assembly and the front suspension member body mounting rear cushion.

HINT:

Perform the same procedure as for the front suspension member body mounting rear cushion LH.

4. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION (for LH Side)

(a) Align a new front suspension member body mounting front cushion as shown in the illustration and set it to the front frame assembly.

*a	View from Underneath
	Front of the Vehicle

(b) Install SST as shown in the illustration. SST: 09830-10010 09830-01010 09830-01020 09830-01030 09830-01060 NOTICE: Be sure to install SST (09830-01030) in the correct direction. Apply molybdenum grease to the threads and tip of the SST center bolt before use.

*1 Front Suspension Member Body Mounting Front Cushion

(c) Using SST, install the front suspension member body mounting front cushion as shown in the illustration.

*a	Hold
	Turn

NOTICE:

Check that there is no clearance between the front frame assembly and the front suspension member body mounting front cushion.

5. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION (for RH Side)

(a) Align a new front suspension member body mounting front cushion as shown in the illustration and set it to the front frame assembly.

*a	View from Underneath
	Front of the Vehicle

(b) Install SST using the same procedure as for the LH side.

SST: 09830-10010

09830-01010

09830-01020

09830-01030

09830-01060

(c) Using SST, install the front suspension member body mounting front cushion.

NOTICE:

Check that there is no clearance between the front frame assembly and the front suspension member body mounting front cushion.

HINT:

Perform the same procedure as for the LH side.

6. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR STOPPER

(a) Install the 2 front suspension member body mounting rear stoppers to the front frame assembly.

7. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING FRONT STOPPER

(a) Install the 2 front suspension member body mounting front stoppers to the front frame assembly.

8. INSTALL FRONT SUSPENSION MEMBER DYNAMIC DAMPER (for A25A-FKS, 2GR-FKS)

(a) Install the front suspension member dynamic damper to the front frame assembly with the 2 bolts.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

9. INSTALL BOLT (for A25A-FXS)

(a) Install the 2 bolts to the front frame assembly.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

10. INSTALL NO. 2 EXHAUST PIPE SUPPORT BRACKET

(a) Install the No. 2 exhaust pipe support bracket to the front frame assembly with the 2 bolts.

Torque:

29 N·m {296 kgf·cm, 21 ft·lbf}

11. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

(a) Install the front lower arm bushing stopper to the front lower No. 1 suspension arm sub-assembly LH.

(b) Install the front lower No. 1 suspension arm sub-assembly LH to the front frame assembly with the 3 bolts and nut in the order shown in the illustration. Torque: Bolt (1), (2) : 200 N·m {2039 kgf·cm, 148 ft·lbf} Bolt (3) : 135 N·m {1377 kgf·cm, 100 ft·lbf} NOTICE: Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.

12. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

13. INSTALL RACK AND PINION POWER STEERING GEAR ASSEMBLY

Click here

14. INSTALL FRONT STABILIZER BAR WITH BRACKET

Click here

15. INSTALL FRONT FRAME ASSEMBLY

(a) Install the rear engine mounting insulator to the front frame assembly with the 4 nuts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

(b) Install the front engine mounting insulator to the front frame assembly with the 3 nuts.

Torque:

72 N·m {734 kgf·cm, 53 ft·lbf}

16. REMOVE ENGINE HANGERS (for 2GR-FKS)

Click here

17. CONNECT WIRE HARNESS

Click here

18. INSTALL STEERING GEAR HEAT INSULATOR (for A25A-FKS, A25A-FXS)

Click here

19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

for A25A-FKS: Click here

for A25A-FXS: Click here

for 2GR-FKS: Click here

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