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 THROTTLE BODY GASKET

(a) Install a new throttle body gasket to the intake manifold with the protrusion of the throttle body gasket oriented as shown in the illustration.

*a Protrusion

2. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

HINT:

Perform "Inspection After Repair" after replacing the throttle body with motor assembly.

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(a) Connect the No. 6 water by-pass hose to the throttle body with motor assembly and slide the clip to secure it. NOTICE: If the throttle body with motor assembly has been struck or dropped, replace it. Make sure to position the clip as shown in the illustration.

*a 45°(Claw of Clip Location) *b Left of Vehicle *c Top *d Paint Mark

(b) Using an 8 mm socket wrench, install the throttle body with motor assembly to the intake manifold with the 3 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

*a 45°(Claw of Clip Location) *b Down *c Right of Vehicle

(c) Connect the No. 5 water by-pass hose to the throttle body with motor assembly and slide the clip to secure it.

NOTICE:

Make sure to position the clip as shown in the illustration.

(d) Connect the throttle body with motor assembly connector.

3. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

(a) Install the air cleaner cap with air cleaner hose to the throttle body with motor assembly. NOTICE: Align the cutout of the air cleaner hose assembly with the protrusion of the throttle body with motor assembly.

*a Protrusion *b Cutout *c Hose Clamp End *d Paint Mark *e 2 mm (0.0787 in.) *f 4 mm (0.157 in.) *g End of Hose Clamp Location

(b) Tighten the hose clamp in the position shown in the illustration.

NOTICE:

Make sure that the end of the hose clamp is positioned as shown in the illustration.

(c) Engage the 2 guides to install the air cleaner cap sub-assembly to the air cleaner case sub-assembly.

(d) Engage the 2 air cleaner cap clamps.

(e) Connect the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it. NOTICE: Make sure to position the clip as shown in the illustration.

*a Top *b Front of Vehicle *c 45°(Claw of Clip Location) *d Paint Mark

(f) Engage the wire harness clamp.

(g) Connect the mass air flow meter sub-assembly connector.

4. INSTALL INLET AIR CLEANER ASSEMBLY

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5. INSTALL COOL AIR INTAKE DUCT SEAL

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6. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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7. ADD ENGINE COOLANT (for Engine)

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8. INSPECT FOR COOLANT LEAK (for Engine)

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9. PERFORM INITIALIZATION

(a) Connect the Techstream to the DLC3.

(b) Turn the power switch on (IG).

(c) Turn the Techstream on.

(d) Clear the DTCs.

(e) Perform "Inspection After Repair".

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(f) Put the engine in Inspection Mode (Maintenance Mode).

(g) Start the engine and check that the MIL is not illuminated. After the engine is warmed up, check that the idle speed is within the specified range with the A/C switch off.

Standard Idle Speed:

1050 to 1150 rpm

(h) Perform a road test and confirm that there are no abnormalities.

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