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. |
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(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. |
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(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:
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(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:
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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 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
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15. INSTALL FRONT FLOOR COVER LH
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16. INSTALL FRONT FLOOR COVER RH
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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
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21. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH
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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
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Inspection
INSPECTION PROCEDURE 1. INSPECT REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY LH (for 2WD) (a) Preparation for check (1) Confirm the standard, high and low positions of the link that will be used in the following inspection.
The standard position is 58° from the maximum link angle (high) and 51° from
Disassembly
DISASSEMBLY CAUTION / NOTICE / HINT NOTICE: This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts. Click here PROCEDURE 1. REMOVE SPARK PLUG Click here 2. REMOVE KNOCK CONTROL SENSOR Click here 3. REMOVE ENGINE
