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 VACUUM HOSE
(a) Install the vacuum hose to the intake manifold.
2. INSTALL NO. 1 ENGINE COVER
(a) Install the No. 1 engine cover with the clip.
3. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET
(a) Install a new No. 1 intake manifold to head gasket to the intake manifold.
4. INSTALL INTAKE MANIFOLD
(a) w/o Stud Bolt:
| (1) Temporarily install the intake manifold to the cylinder head sub-assembly with the 5 bolts. |
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(2) Tighten the 5 bolts in the order shown in the illustration.
Torque:
24 N·m {245 kgf·cm, 18 ft·lbf}
(b) w/ Stud Bolt:
| (1) Temporarily install the intake manifold to the cylinder head sub-assembly. |
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(2) Using an E8 "TORX" socket wrench, install the 2 stud bolts.
Torque:
6.5 N·m {66 kgf·cm, 58 in·lbf}
| (3) Temporarily install the 3 bolts and 2 nuts. |
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(4) Tighten the 3 bolts and 2 nuts in the order shown in the illustration.
Torque:
24 N·m {245 kgf·cm, 18 ft·lbf}
5. INSTALL NO. 2 FUEL VAPOR FEED HOSE
(a) Install the No. 2 fuel vapor feed hose to the intake manifold.
6. INSTALL NO. 2 WATER BY-PASS PIPE
| (a) Temporarily install the No. 2 water by-pass pipe to the cylinder block sub-assembly with the bolt (B). |
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(b) Using an 8 mm socket wrench, temporarily install the No. 2 water by-pass pipe to the intake manifold with the 2 bolts (A).
(c) Tighten the bolt (B).
Torque:
21 N·m {214 kgf·cm, 15 ft·lbf}
(d) Using the 8 mm socket wrench, tighten the 2 bolts (A).
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
(e) Engage the wire harness clamp to connect the HV air conditioning wire.
7. CONNECT NO. 3 WATER BY-PASS PIPE
(a) Using an 8 mm socket wrench, connect the No. 3 water by-pass pipe to the intake manifold with the bolt.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
(b) Connect the No. 5 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.
8. CONNECT ENGINE WIRE
| (a) Engage the wire harness clamp to connect the engine wire to the intake manifold. |
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(b) Install the bolt.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
| (c) Connect the engine wire to the cylinder head sub-assembly with the bolt. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} |
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(d) Connect the No. 5 engine wire connector.
9. INSTALL PURGE VALVE (PURGE VSV)
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10. INSTALL E.F.I. VACUUM SENSOR ASSEMBLY (MANIFOLD ABSOLUTE PRESSURE SENSOR)
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11. INSTALL EGR VALVE ASSEMBLY
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12. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY
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