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 EGR VALVE ASSEMBLY

HINT:

Perform "Inspection After Repair" after replacing the EGR valve assembly.

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(a) Using an 8 mm socket wrench, install the EGR valve assembly to the EGR valve bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) Align and fit the hole of the EGR valve bracket to the pin of the camshaft housing.

*a Pin *b Hole

(c) Using the 8 mm socket wrench, install the EGR valve assembly with the EGR valve bracket to the camshaft housing with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(d) for EGR Valve Bracket Connection Type:

(1) Using the 8 mm socket wrench, connect the fuel pipe sub-assembly to the EGR valve bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(e) Connect the No. 4 water by-pass hose and No. 8 water by-pass hose to the EGR valve assembly and slide the 2 clips to secure them.

2. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

(a) Install a new EGR inlet gasket to the intake manifold.

(b) Install a new EGR valve adapter gasket to the No. 1 EGR pipe sub-assembly.

(c) Using an 8 mm socket wrench, install the No. 1 EGR pipe sub-assembly to the intake manifold and EGR valve assembly with the 4 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

3. CONNECT EGR COOLER ASSEMBLY

(a) Install a new EGR valve gasket to the EGR valve assembly. NOTICE: Make sure that the claws of the EGR valve gasket are toward the EGR valve assembly side.

*a Claw

(b) Connect the EGR cooler assembly to the EGR valve assembly with the 2 bolts.

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

4. CONNECT ENGINE WIRE

(a) Engage the 2 wire harness clamps to connect the engine wire.

(b) Install the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(c) Connect the EGR valve assembly connector.

(d) Engage the 3 hose clamps to connect the No. 1 fuel vapor feed hose and No. 2 fuel vapor feed hose.

*1 No. 1 Fuel Vapor Feed Hose *2 No. 2 Fuel Vapor Feed Hose

5. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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6. ADD ENGINE COOLANT (for Engine)

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7. INSPECT FOR COOLANT LEAK (for Engine)

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8. INSPECT FOR EXHAUST GAS LEAK

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9. PERFORM INITIALIZATION

(a) Perform "Inspection After Repair" after replacing the EGR valve assembly.

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