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Installation [11/2021 - ]: Procedure

WARNING: This page is about a different car, the 2024 Lexus IS 500, 2023 Lexus IS 500, and 2022 Lexus IS 500. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL ENGINE HANGER 

    See step  50

  2. REMOVE ENGINE FROM ENGINE STAND 
    1. Remove the engine assembly from the engine stand.
  3. INSTALL FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the front engine mounting insulator is necessary.

    1. Install the 2 front engine mounting insulators to the front suspension crossmember sub-assembly with the 2 nuts.

      Torque: 70 N.m (714 kgf/cm, 52 ft.lbf) 

    2. Install the 2 engine mounting spacers.
  4. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Install the front suspension crossmember sub-assembly to the engine assembly with the 2 nuts.

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

  5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  2

  6. INSTALL NO. 1 ENGINE MOUNTING BRACKET 
    1. Install the No. 1 engine mounting bracket to the automatic transmission assembly with the 4 bolts.

      Torque: 52 N.m (530 kgf/cm, 38 ft.lbf) 

  7. INSTALL REAR ENGINE MOUNTING HEAT INSULATOR 
    1. Install the rear engine mounting heat insulator to the rear engine mounting insulator.
  8. INSTALL REAR ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

    1. Install the rear engine mounting insulator to the automatic transmission assembly with the 4 nuts.

      Torque: 13 N.m (133 kgf/cm, 10 ft.lbf) 

      HINT: 

      Make sure that the claw is facing towards the front of the vehicle.

  9. INSTALL REAR ENGINE MOUNTING MEMBER 

    HINT: 

    Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

    1. Install the rear engine mounting member to the rear engine mounting insulator with the 4 nuts.

      Torque: 13 N.m (133 kgf/cm, 10 ft.lbf) 

  10. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY 

    Refer to PROCEDURE - Step 4

  11. CONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 5

  12. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT 

    Refer to PROCEDURE - Step 9

  13. INSTALL FLYWHEEL HOUSING SIDE COVER 

    Refer to PROCEDURE - Step 1

  14. INSTALL STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 2

  15. INSTALL GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  16. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY 
    1. Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

      Torque: 24.5 N.m (250 kgf/cm, 18 ft.lbf) 

      HINT: 

      Tighten the bolts and nuts in the order shown in the illustration.

      Fig 1: Compressor Assembly With Pulley Bolts And Nuts Tightening Sequence
      GTY1084220Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  17. INSTALL OIL COOLER TUBE 
    1. Install the oil cooler tube with the 3 bolts.

      Torque: 13.5 N.m (138 kgf/cm, 10 ft.lbf) 

    2. Engage the clamp.
  18. INSTALL V-RIBBED BELT 

    See step  1

  19. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 3

  20. INSTALL EXHAUST MANIFOLD TO HEAD GASKET LH 

    Refer to PROCEDURE - Step 7

  21. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 8

  22. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 9

  23. INSTALL EXHAUST MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 1

  24. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 2

  25. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 3

  26. INSTALL ENGINE MOUNTING DAMPER 
    1. Install the 2 engine mounting dampers with the 2 bolts.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

  27. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY RH 
    1. Engage the 2 clamps to install the engine under cover sub-assembly RH to the front suspension crossmember sub-assembly.
  28. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY LH 
    1. Engage the 2 clamps to install the engine under cover sub-assembly LH to the front suspension crossmember sub-assembly.
  29. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 4

  30. INSTALL ENGINE OIL LEVEL DIPSTICK 

    Refer to PROCEDURE - Step 5

  31. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION 
    1. Set the engine assembly with transmission on an engine lifter.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transmission horizontally.
      • Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
      • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transmission.
    2. Remove the 2 bolts and 2 No. 1 engine hangers.
    3. Install the engine assembly with transmission to the vehicle.
      NOTE:

      Make sure that the engine assembly with transmission is clear of all wiring and hoses.

    4. Install the strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly with the 6 bolts and 2 nuts.

      Bolt (A) 

      Torque: 194 N.m (1978 kgf/cm, 143 ft.lbf) 

      Bolt (B) 

      Torque: 57 N.m (581 kgf/cm, 42 ft.lbf) 

      Nut 

      Torque: 151 N.m (1540 kgf/cm, 111 ft.lbf) 

      GTY1084142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    5. Connect the front No. 2 stabilizer bracket LH and front No. 2 stabilizer bracket RH with the 4 bolts.

      Bolt (C) 

      Torque: 49 N.m (500 kgf/cm, 36 ft.lbf) 

    6. Install the rear engine mounting member to the vehicle body with the 4 bolts.

      Torque: 34.7 N.m (354 kgf/cm, 26 ft.lbf) 

    7. Install the No. 1 frame crossmember assembly and No. 2 frame crossmember assembly with the 6 bolts.

      Torque: 20 N.m (204 kgf/cm, 15 ft.lbf) 

    8. Connect the No. 2 earth wire to the vehicle body with the nut.

      Torque: 5.4 N.m (55 kgf/cm, 48 in.lbf) 

  32. INSTALL SUSPENSION TOWER DAMPER 

    Refer to PROCEDURE - Step 1

  33. CONNECT WIRE HARNESS 
    1. Engage the 2 wire harness clamps to the power steering link assembly.
    2. Connect the 3 power steering link assembly connectors.

      HINT: 

      For the connector with lock lever, fully insert the connector and push down the lock lever to engage the lock.

  34. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  35. INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  36. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH 

    Refer to PROCEDURE - Step 2

  37. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  38. CONNECT FRONT SHOCK ABSORBER ASSEMBLY LH 
    1. Connect the front shock absorber assembly LH to the front suspension lower arm assembly LH with the bolt and nut.

      Torque: 108 N.m (1101 kgf/cm, 80 ft.lbf) 

      NOTE:
      • Insert the bolt from the rear of the vehicle.
      • Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.
  39. CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  40. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 

    Refer to INSTALLATION [11/2021 - ]

  41. CONNECT WIRE HARNESS 
    1. Connect the ground cable to the generator assembly with the bolt.

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

    2. Engage the clamp.
    3. Engine room LH side:
      1. Engage the engine wire clamp.
      2. Connect the engine wire to the engine room ECU box.

        Refer to PROCEDURE - Step 4

    4. Engine room RH side:
      1. Connect the engine wire to the vehicle body with the bolt.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      2. Engage the 2 claws to connect the engine wire to the No. 1 engine room relay block and No. 1 junction block assembly.
      3. Engage the 2 engine wire clamps.
      4. Install the nut to the No. 1 engine room relay block and No. 1 junction block assembly.

        Torque: 10.5 N.m (107 kgf/cm, 8 ft.lbf) 

      5. Install the No. 1 engine room relay block cover to the No. 1 engine room relay block and No. 1 junction block assembly.
      6. Connect the No. 2 engine wire to the positive (+) battery terminal with the nut.

        Torque: 7.6 N.m (77 kgf/cm, 67 in.lbf) 

      7. Engage the No. 2 engine wire clamp.
      8. Engage the 4 clamps to install the No. 1 center cowl top ventilator louver to the cowl top ventilator louver sub-assembly.
  42. INSTALL ENGINE ROOM ECU COVER 

    Refer to PROCEDURE - Step 5

  43. CONNECT SUCTION HOSE 

    Refer to PROCEDURE - Step 8 [11/2021 - 09/2022] , or refer to PROCEDURE - Step 8 [09/2022 - ]

  44. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 11 [11/2021 - 09/2022] , or refer to PROCEDURE - Step 11 [09/2022 - ]

  45. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube sub-assembly.

      Refer to PRECAUTION [11/2021 - 09/2022] , or refer to PRECAUTION [09/2022 - ]

    2. Install the fuel pipe clamp.
  46. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY 
    1. Connect the No. 2 fuel tube sub-assembly.

      Refer to PRECAUTION [11/2021 - 09/2022] , or refer to PRECAUTION [09/2022 - ]

    2. Install the fuel pipe clamp.
  47. CONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Connect the No. 1 fuel vapor feed hose to the purge valve (purge VSV) and slide the clip to secure it.
  48. CONNECT UNION TO CHECK VALVE HOSE 
    1. Connect the union to check valve hose to the brake booster assembly and slide the clip to secure it.
    2. Engage the clamp to connect the union to check valve hose.
  49. CONNECT HEATER WATER INLET HOSE 
    1. Connect the heater water inlet hose to the water by-pass pipe sub-assembly and slide the clip to secure it.
    2. Install the water hose set.
  50. CONNECT HEATER WATER OUTLET HOSE 
    1. Connect the heater water outlet hose to the water by-pass pipe sub-assembly and slide the clip to secure it.
    2. Install the water hose set.
  51. CONNECT NO. 1 OIL COOLER OUTLET HOSE 
    1. Connect the No. 1 oil cooler outlet hose to the oil cooler tube and slide the clip to secure it.
  52. CONNECT NO. 1 OIL COOLER INLET HOSE 
    1. Connect the No. 1 oil cooler inlet hose to the oil cooler tube and slide the clip to secure it.
  53. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the water inlet housing and slide the clip to secure it.
  54. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the front water by-pass joint and slide the clip to secure it.
  55. INSTALL RADIATOR RESERVE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 11

  56. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Install the air cleaner case sub-assembly with the 2 bolts.

      Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

    2. Engage the clamp to connect the vacuum switching valve connector.
    3. Engage the 2 clamps and connect the vacuum hose assembly.
  57. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
    1. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.
  58. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 2

  59. CONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 3

  60. INSTALL INLET NO. 1 AIR CLEANER 

    Refer to PROCEDURE - Step 15

  61. INSTALL ENGINE UNDER COVER AIR GUIDE BRACKET 

    Refer to PROCEDURE - Step 3

  62. INSTALL NO. 2 ENGINE UNDER COVER 
    1. Install the No. 2 engine under cover with the 2 screws.
  63. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR 
    1. Install the front lower suspension member protector with the 4 bolts.

      Torque: 5.5 N.m (56 kgf/cm, 49 in.lbf) 

  64. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY 
    1. Install the front suspension member brace sub-assembly with the 6 bolts and 4 nuts.

      Bolt 

      Torque: 52 N.m (530 kgf/cm, 38 ft.lbf) 

      Nut 

      Torque: 19 N.m (194 kgf/cm, 14 ft.lbf) 

  65. INSTALL REAR ENGINE UNDER COVER LH 
    1. Install the rear engine under cover LH with the screw.
  66. INSTALL REAR ENGINE UNDER COVER RH 

    HINT: 

    Perform the same procedure as for the LH side.

  67. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [11/2021 - 09/2022] , or refer to INITIALIZATION [09/2022 - 10/2023] , or refer to INITIALIZATION [10/2023 - ]

  68. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 5

  69. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 4

  70. ADD AUTOMATIC TRANSMISSION FLUID 

    Refer to ADJUSTMENT [11/2021 - ]

  71. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  72. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  73. INSPECT SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 1

  74. ADJUST SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 3

  75. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  76. INSPECT FOR ENGINE OIL LEAK 

    Refer to PROCEDURE - Step 6

  77. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  78. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 9

  79. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 4

  80. INSTALL FRONT WHEELS 

    Refer to PROCEDURE - Step 1 [09/2020 - 10/2023] , or refer to PROCEDURE - Step 2 [10/2023 - ]

  81. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  82. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [11/2021 - ]

  83. PERFORM INITIALIZATION 

    Refer to INITIALIZATION [11/2021 - 09/2022] , or refer to INITIALIZATION [09/2022 - 10/2023] , or refer to INITIALIZATION [10/2023 - ]

  84. INSPECT IGNITION TIMING 

    See step  8

  85. INSPECT ENGINE IDLE SPEED 

    See step  9

  86. INSPECT CO/HC 

    See step  11

  87. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR 

    Refer to PROCEDURE - Step 2

  88. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1 [11/2021 - 10/2023] , or refer to PROCEDURE - Step 1 [10/2023 - ]

  89. INSTALL ENGINE UNDER COVER 
    1. Install the engine under cover with the 13 screws and 3 clips.
  90. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 2

  91. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Attach the 4 clips in the order shown in the illustration to install the V-bank cover sub-assembly.
      Fig 2: V-Bank Cover Sub-Assembly Tightening Sequence
      GTY1084181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Tip (Sphere)
      NOTE:
      • Securely attach the clips.
      • If the clips are forcibly attached or struck with an object, they may be damaged.
      • Do not apply any oil to the tips (sphere).
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