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. |
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(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. |
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(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. |
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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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READ NEXT:
Parts Location
PARTS LOCATION ILLUSTRATION *1 CANISTER (CHARCOAL CANISTER ASSEMBLY) *2 EGR VALVE ASSEMBLY *3 FUEL TANK CAP ASSEMBLY *4 FUEL VAPOR CONTAINMENT VALVE (FUEL TANK SOLENOID MAIN VALVE
System Diagram
SYSTEM DIAGRAM *1 Intake Manifold *2 Purge Valve (Purge VSV) *3 Throttle Valve *4 Canister (Charcoal Canister Assembly) *5 Air Cleaner *6 ECM *7 Canister Filter *
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