Lexus ES manuals

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 CYLINDER HEAD GASKET

(a) Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.

(b) Place a new cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.

*a

Lot No.

Front of Engine

NOTICE:

  • Make sure that the cylinder head gasket is installed in the correct orientation.
  • Remove any oil from the contact surfaces.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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3. INSTALL NO. 2 CAMSHAFT

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4. INSTALL CAMSHAFT

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5. INSTALL CAMSHAFT BEARING CAP

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6. INSTALL VALVE STEM CAP

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7. INSTALL VALVE LASH ADJUSTER ASSEMBLY

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8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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9. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

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10. INSTALL FUEL PUMP LIFTER GUIDE

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11. INSTALL TIMING CHAIN COVER ASSEMBLY

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12. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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13. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

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14. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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15. INSTALL CHAIN TENSIONER SLIPPER

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16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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17. INSTALL CHAIN SUB-ASSEMBLY

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18. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

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19. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

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20. SET NO. 1 CYLINDER TO TDC (COMPRESSION)

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21. INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY

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22. INSTALL TIMING CHAIN COVER OIL SEAL

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23. INSTALL SPARK PLUG TUBE GASKET

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24. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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25. INSTALL WATER BY-PASS OUTLET SUB-ASSEMBLY

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26. INSTALL WATER OUTLET

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27. INSTALL CRANKSHAFT PULLEY ASSEMBLY

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28. INSTALL CAM TIMING CONTROL MOTOR O-RING

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29. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

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30. INSTALL O-RING

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31. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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32. INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY

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33. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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34. INSTALL IGNITION COIL ASSEMBLY

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35. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

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36. INSTALL FUEL DELIVERY PIPE

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37. INSTALL PORT FUEL INJECTOR ASSEMBLY

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38. INSTALL NO. 5 ENGINE WIRE

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39. INSTALL INJECTOR VIBRATION INSULATOR

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40. INSTALL NO. 1 DELIVERY PIPE SPACER

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41. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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42. INSTALL NO. 7 WATER BY-PASS HOSE

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43. TEMPORARILY INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

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44. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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45. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

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46. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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47. CONNECT FUEL TUBE SUB-ASSEMBLY

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48. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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49. INSTALL INTAKE MANIFOLD

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50. INSTALL NO. 2 WATER BY-PASS PIPE

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51. INSTALL NO. 3 WATER BY-PASS PIPE

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52. INSTALL EGR VALVE ASSEMBLY

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53. INSTALL NO. 4 WATER BY-PASS HOSE

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54. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

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55. INSTALL EGR COOLER ASSEMBLY

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56. INSTALL THROTTLE BODY GASKET

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57. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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58. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

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59. INSTALL MANIFOLD STAY

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60. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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61. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

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62. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

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63. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

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64. INSTALL ENGINE HANGERS

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65. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

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