Lexus ES: Reassembly

*a

Protrusion Height

-

-

(1) Using a plastic hammer, tap in a new straight pin to the timing chain cover assembly.

Standard Protrusion Height:

18.5 to 19.5 mm (0.728 to 0.768 in.)

(1) Using a plastic hammer, tap in 10 new ring pins to the camshaft housing sub-assembly.

Standard Protrusion Height:

3.2 to 4.3 mm (0.126 to 0.169 in.)

(1) Using a plastic hammer, tap in 6 new ring pins to the stiffening crankcase assembly.

Standard Protrusion Height:

Ring Pin (A)

3.5 to 4.5 mm (0.138 to 0.177 in.)

Ring Pin (B)

4.3 to 5.3 mm (0.169 to 0.209 in.)

(1) Using a plastic hammer, tap in a new ring pin to the timing chain cover assembly.

Standard Protrusion Height:

3.0 to 5.0 mm (0.118 to 0.197 in.)

(1) Using an E6 "TORX" socket wrench, install the 2 stud bolts to the stiffening crankcase assembly.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

(1) Using an E6 "TORX" socket wrench, install the stud bolt to the timing chain cover assembly.

Torque:

4.0 N·m {41 kgf·cm, 35 in·lbf}

(1) Install the wire harness clamp bracket to the stiffening crankcase assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(1) Install the wire harness clamp bracket to the cylinder block sub-assembly with the bolt.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

(1) Install the wire harness clamp bracket to the camshaft housing sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(a) Using a 10 mm hexagon socket wrench, install the 3 straight screw plugs and 3 new gaskets to the stiffening crankcase assembly.

Torque:

44 N·m {449 kgf·cm, 32 ft·lbf}

(a) Install the engine balancer assembly to the stiffening crankcase assembly with the 2 bolts.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

(a) Rotate the crankshaft clockwise so that the crankshaft timing gear key groove is at the position 270° from the bottom as shown in the illustration.

(b) Apply seal packing in a continuous line as shown in the illustration.

Seal Packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Standard Seal Packing Dimension:

(c) Check that the front cutouts are as shown in the illustration.

(e) Temporarily install the stiffening crankcase assembly with the 11 bolts.

Bolt Length :

(f) Tighten the 11 bolts in the order shown in the illustration to install the stiffening crankcase assembly.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

(a) Install the oil pump bracket with the 2 bolts as shown in the illustration.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

(b) Using an 8 mm socket wrench, install the oil strainer sub-assembly and oil strainer gasket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(a) Apply seal packing in a continuous line as shown in the illustration.

Seal Packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Standard Seal Packing Diameter:

2.5 to 3.5 mm (0.0984 to 0.138 in.)

(b) Install the No. 2 oil pan sub-assembly with the 11 bolts and 2 nuts in several steps in the order shown in the illustration.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(a) Using a 12 mm hexagon socket wrench, install the oil filter union to the stiffening crankcase assembly.

Torque:

29.5 N·m {301 kgf·cm, 22 ft·lbf}

(a) Install the cylinder block water jacket spacer to the exhaust side of the cylinder block sub-assembly.

Bolt (A)

139.1 to 140.9 mm (5.48 to 5.55 in.)

Bolt (B)

149.1 to 150.9 mm (5.87 to 5.94 in.)

Front of Engine

Front of Engine

*a

Paint Mark

*b

90°

*c

90°

Front of Engine

(a) Using an 8 mm socket wrench, install the water seal plate and a new gasket to the cylinder head sub-assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Using a 14 mm straight hexagon wrench, install the No. 3 straight screw plug to the cylinder head sub-assembly.

Torque:

60 N·m {612 kgf·cm, 44 ft·lbf}

(c) Install the No. 2 camshaft to the camshaft housing sub-assembly.

(c) Install the camshaft to the camshaft housing sub-assembly.

(a) Place the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 2 No. 3 camshaft bearing caps and No. 4 camshaft bearing cap in their correct locations.

(b) Uniformly tighten the 8 bolts in the order shown in the illustration.

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

(b) Install the 16 valve stem caps to the cylinder head sub-assembly.

(b) Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

NOTICE:

Install the same parts in the same combination to their original locations.

(a) Apply engine oil to the valve lash adjuster assembly tips and valve stem caps.

(a) Check that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

(b) Apply seal packing in a continuous line as shown in the illustration.

Seal Packing:

Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Standard Seal Packing Diameter:

3.0 to 4.0 mm (0.118 to 0.157 in.)

(c) Position the camshaft and No. 2 camshaft as shown in the illustration.

(d) Temporarily install the camshaft housing sub-assembly with the 18 bolts.

Bolt Length :

(e) Tighten the 18 bolts in several steps in the order shown in the illustration.

Torque:

28.5 N·m {291 kgf·cm, 21 ft·lbf}

NOTICE:

After installation, if the seal packing has seeped out, wipe it off.

(a) Using an 8 mm socket wrench, install the fuel pump lifter guide to the No. 4 camshaft bearing cap with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(a) Using a plastic hammer, tap in the 2 crankshaft timing gear keys.

HINT:

Tap in the crankshaft timing gear keys until they contact the crankshaft as shown in the illustration.

(a) Install the oil nozzle valve sub-assembly to the cylinder block sub-assembly.

*a

Timing Chain Cover Assembly Side

*b

Engine Assembly Side

*a

2.5 to 3.5 mm (0.0984 to 0.138 in.)

*b

2.0 to 6.0 mm (0.0787 to 0.236 in.)

*c

10 mm (0.394 in.)

*d

20 mm (0.787 in.)

*e

4.0 to 6.0 mm (0.157 to 0.236 in.)

*f

3.0 to 4.0 mm (0.118 to 0.157 in.)

*g

8.0 to 10 mm (0.315 to 0.394 in.)

*h

30 mm (1.18 in.)

Seal Packing

-

-

(c) Temporarily install the timing chain cover assembly with the 19 bolts.

Bolt Length:

NOTICE:

Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.

(d) Tighten the 19 bolts in the order shown in the illustration.

Torque:

27 N·m {275 kgf·cm, 20 ft·lbf}

(a) Align and fit the knock pin of the No. 2 camshaft to the knock pin hole of the camshaft timing exhaust gear assembly.

(1) Apply a light coat of engine oil to the O-ring of the camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly).

NOTICE:

If reusing the camshaft timing oil control valve assembly (exhaust camshaft timing gear bolt assembly), be sure to inspect the O-ring.

(2) Using a wrench, hold the hexagonal portion of the No. 2 camshaft.

NOTICE:

Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.

(1) Using a wrench, hold the hexagonal portion of the No. 2 camshaft.

NOTICE:

Be careful not to damage the camshaft housing sub-assembly, cylinder head sub-assembly and spark plug tube with the wrench.

(b) Rotate the crankshaft 44.2° counterclockwise to position the crankshaft timing gear key as shown in the illustration.

(c) Check that the timing marks of the camshaft timing exhaust gear assembly and knock pin are as shown in the illustration.

(a) Install the No. 1 chain vibration damper with the 2 bolts.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

(a) Install the chain tensioner slipper with the bolt.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

(a) While slightly pushing in the plunger of the No. 1 chain tensioner assembly, install the chain tensioner slipper.

(b) Using an 8 mm socket wrench, install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(a) Set the crankshaft timing gear key as shown in the illustration.

(c) Install the crankshaft timing sprocket and chain sub-assembly.

(d) Align the paint mark (yellow) of the chain sub-assembly with the timing mark of the crankshaft timing sprocket and install the chain sub-assembly to the crankshaft timing sprocket.

*a

Paint Mark (Pink)

*b

Timing Mark

Turn

(a) Hold the hexagonal portion of the No. 2 camshaft with a wrench and turn the camshaft timing exhaust gear assembly clockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and crankshaft timing sprocket as shown in the illustration.

(b) Align the paint mark (pink) of the chain sub-assembly and the timing mark of the camshaft timing gear assembly.

(c) Align and fit the knock pin of the camshaft to the knock pin hole of the camshaft timing gear assembly.

*a

Hold

Turn

*1

Oil Pump Drive Sprocket

*2

Oil Pump Drive Shaft Sprocket

*3

Crankshaft Timing Gear Key

*4

Oil Pump Assembly

*a

Mark Plate

*b

Timing Mark

(e) Install the chain damper spring to the chain tensioner plate, and then install the chain tensioner plate.

(g) Using SST, hold the crankshaft pulley assembly and install the bolt.

SST: 09213-54015

SST: 09330-00021

Torque:

50 N·m {510 kgf·cm, 37 ft·lbf}

*a

No. 2 Timing Chain Cover Assembly Side

*b

Timing Chain Cover Assembly Side

Seal Packing

(c) Temporarily install the No. 2 timing chain cover assembly to the timing chain cover assembly with the 20 bolts.

NOTICE:

Make sure there is no oil on the bolts. If oil is found on any bolt, clean it before installation.

(f) Tighten the 3 bolts in the order shown in the illustration.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

NOTICE:

After applying seal packing to the No. 2 timing chain cover assembly, install the engine mounting bracket RH within 10 minutes.

(b) Using a 10 mm hexagon wrench, install the straight screw plug to the No. 2 timing chain cover assembly.

Torque:

40 N·m {408 kgf·cm, 30 ft·lbf}

(a) Install 4 new spark plug tube gaskets to the cylinder head cover sub-assembly.

(b) Install the camshaft bearing cap oil hole gasket to the No. 1 camshaft bearing cap.

*a

Seal Packing Diameter: 3.0 to 6.0 mm

*b

Mark

Seal Packing

(e) Using an 8 mm socket wrench, install the 2 camshaft position sensors (for Exhaust Side and for Intake Side) with 2 new bolts (B) and cylinder head cover sub-assembly with 4 new bolts (C) and 12 bolts (A) in the order shown in the illustration.

Bolt Length:

Torque:

7.5 N·m {76 kgf·cm, 66 in·lbf}

HINT:

After tightening all bolts, check the tightening torque of the bolts (7) and (8). Retighten them if necessary.

(a) Using an 8 mm socket wrench, install the water by-pass outlet sub-assembly and a new outlet water pipe gasket to the cylinder head sub-assembly with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(a) Using an 8 mm socket wrench, install the water outlet and a new water outlet gasket to the cylinder head sub-assembly with the 3 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

*a

Hold

Turn

(a) Install a new oil filler cap gasket to the oil filler cap sub-assembly.

(a) Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

(a) Install the straight screw plug and a new gasket to the cylinder block sub-assembly.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}