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Installation [08/2021 - ]: Procedure

WARNING: This page is about a different car, the 2024 Lexus ES 250, 2023 Lexus ES 250, 2022 Lexus ES 250, and 2021 Lexus ES 250. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL STUD BOLT 
    1. Using an E8 "TORX" socket wrench, install the stud bolt to the timing chain cover assembly.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

  2. INSTALL NO. 2 VACUUM SWITCHING VALVE BRACKET 
    1. Using an 8 mm socket wrench, install the No. 2 vacuum switching valve bracket to the cylinder head sub-assembly with the 2 bolts.

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

  3. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 1

  4. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the No. 3 exhaust manifold heat insulator to the cylinder block sub-assembly with the bolt.

      Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) 

  5. INSTALL ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING) 
    1. Install the engine water pump assembly (water inlet housing) and a new gasket to the cylinder block sub-assembly with the 4 bolts.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

  6. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  7. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Apply a light coat of engine oil to a new O-ring.
    2. Install the O-ring to the engine oil level dipstick guide.
    3. Using an 8 mm socket wrench, install the engine oil level dipstick guide to the camshaft housing sub-assembly with the bolt.

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

    4. Install the engine oil level dipstick.
  8. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  9. INSTALL FUEL INJECTOR SEAL 

    Refer to PROCEDURE - Step 1

  10. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  11. INSTALL FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 3

  12. INSTALL PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  13. INSTALL NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 2

  14. INSTALL INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 3

  15. INSTALL NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 4

  16. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  17. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Using an 8 mm socket wrench, install the wire harness clamp bracket to the No. 1 ventilation case with the 2 bolts.

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

  18. INSTALL NO. 6 ENGINE WIRE 
    1. Install the No. 6 engine wire to the wire harness clamp bracket with the 2 nuts.

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

    2. Engage the 2 clamps.
    3. Connect the 4 connectors.
  19. INSTALL SENSOR WIRE 
    1. Using an 8 mm socket wrench, install the sensor wire to the water inlet with thermostat sub-assembly with the bolt.

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

    2. Engage the 3 clamps.
    3. Connect the 4 connectors.
  20. INSTALL NO. 7 WATER BY-PASS HOSE 
    1. Install the No. 7 water by-pass hose and slide the 2 clips to secure it.
  21. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 1

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

    Refer to PROCEDURE - Step 2

  23. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 3

  24. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.
      GTY948865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Specified tightening torque 

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

      NOTE:

      Do not adjust the torque in the loosening direction.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [06/2018 - ]

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)
    2. Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

      Specified tightening torque 

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

      NOTE:

      Do not adjust the torque in the loosening direction.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [06/2018 - ]

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)
    3. Using an 8 mm socket wrench, install the bolt.

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

  25. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  26. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 3

  27. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 4

  28. INSTALL NO. 2 WATER BY-PASS PIPE 
    1. Temporarily install the No. 2 water by-pass pipe to the cylinder block sub-assembly with the bolt (A).
      GTY1084549Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an 8 mm socket wrench, temporarily install the No. 2 water by-pass pipe to the intake manifold with the 2 bolts (B).
    3. Tighten the bolt (A).

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

    4. Using an 8 mm socket wrench, tighten the 2 bolts (B).

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

  29. INSTALL NO. 3 WATER BY-PASS PIPE 
    1. Install the No. 3 water by-pass pipe to the water outlet and slide the clip to secure it.
    2. 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) 

  30. SET EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  31. INSTALL EGR COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 2

  32. INSTALL EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 3

  33. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  34. INSTALL THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 1

  35. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  36. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 2

  37. INSTALL MANIFOLD STAY 

    Refer to PROCEDURE - Step 3

  38. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 4

  39. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY) 
    1. Connect the flow shutting valve (water by-pass hose assembly) to the outlet water by-pass sub-assembly and slide the clip to secure it.
      GTY754759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b 45° (Claw of Clip Location)
      NOTE:
      • Make sure to slide the flow shutting valve (water by-pass hose assembly) until it contacts the hose stopper of the outlet water by-pass sub-assembly.
      • Make sure that the claws of the clip are within the location shown in the illustration.
    2. Install the water hose clamp bracket with the 2 bolts.

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

    3. Install the flow shutting valve (water by-pass hose assembly) with the bolt.

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

  40. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. Install the No. 2 water by-pass pipe sub-assembly with the bolt.

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

    2. Connect the No. 2 water by-pass pipe sub-assembly to the outlet water by-pass sub-assembly and slide the clip to secure it.
  41. INSTALL TIMING GEAR COVER INSULATOR 
    1. Using an 8 mm socket wrench, install the timing gear cover insulator and plate washer to the No. 2 timing chain cover assembly with the bolt.

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

  42. INSTALL NO. 2 TIMING CHAIN COVER INSULATOR 
    1. Install the No. 2 timing chain cover insulator to the V-ribbed belt tensioner assembly.
  43. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    NOTE:
    • Do not apply or add any oil or grease to the belt tensioner to prevent abnormal noises from the belt tensioner pulley, belt squealing, etc.
    • Do not allow oil or grease to adhere to the moving parts of the belt tensioner, as this may cause malfunctions.
    GTY743260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the V-ribbed belt tensioner assembly to the No. 2 timing chain cover assembly with the 2 bolts.

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

  44. INSTALL NO. 2 ENGINE COVER 
    1. Install the No. 2 engine cover to the No. 2 timing chain cover assembly with the 2 bolts.

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

  45. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY 
    1. Using an E8 "TORX" socket wrench, temporarily install the compressor assembly with pulley with the 2 stud bolts.
      GTY764544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

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

    2. 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.

  46. INSTALL GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  47. INSTALL V-RIBBED BELT 

    Refer to PROCEDURE - Step 1

  48. INSTALL DRIVE SHAFT BEARING BRACKET 
    1. Install the drive shaft bearing bracket with the 3 bolts.

      Torque: 63.7 N*m (650 kgf*cm, 47 ft.*lbf) 

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