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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 REAR NO. 2 ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the rear No. 2 engine mounting insulator is necessary.

    Refer to PROCEDURE - Step 15

  2. INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting bracket sub-assembly LH is necessary.

    1. Install the engine mounting bracket sub-assembly LH to the vehicle body with the 4 bolts.
      GTY893944Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

      NOTE:
      • Temporarily tighten the bolt (A), and then fully tighten the 4 bolts in the order of (B), (C), (D) and (A).
      • Make sure that there is no gap between the engine mounting bracket sub-assembly LH and vehicle body before tightening the bolts.
  3. INSTALL ENGINE MOUNTING SPACER 

    HINT: 

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

    1. Install the engine mounting spacer to the vehicle body with the 2 bolts.

      Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

      NOTE:

      Temporarily tighten the bolt (A), and then fully tighten the 2 bolts in the order of (B) and (A).

      GTY759194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

    1. Install the engine mounting insulator sub-assembly RH with the 2 bolts and nut.
      GTY757548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

      NOTE:

      Temporarily tighten the bolt (A), and then fully tighten the 2 bolts and nut in the order of (B), (A) and (C).

    2. Engage the clamp.
    3. Connect the bracket to the engine mounting insulator sub-assembly RH with the bolt.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    4. Install the radiator reserve tank assembly with the bolt and nut.

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

    5. Engage the clamp.
    6. Connect the No. 6 water by-pass hose.
  5. INSTALL ENGINE HANGERS 

    See step  46 [08/2021 - 09/2022], or see step  46 [09/2022 - ]

  6. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND 
    1. Remove the engine assembly from the engine stand.
  7. INSTALL ENGINE WIRE 
    1. Install the engine wire to the engine assembly.
  8. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE 

    Refer to PROCEDURE - Step 2

  9. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  10. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 16

  11. INSTALL STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  12. INSTALL FLYWHEEL HOUSING SIDE COVER 

    Refer to PROCEDURE - Step 2

  13. INSTALL FRONT ENGINE MOUNTING BRACKET 

    Refer to PROCEDURE - Step 19

  14. 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 front frame assembly with the 4 nuts.

      Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

    2. Install the exhaust sensor clamp bracket with the bolt.

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

    3. Install the wiring harness clamp bracket with the bolt.

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

  15. INSTALL PROPELLER SHAFT HEAT INSULATOR 

    Refer to PROCEDURE - Step 14

  16. INSTALL FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Install the front engine mounting insulator to the front frame assembly with the 3 nuts.

      Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

  17. INSTALL FRONT FRAME ASSEMBLY 
    1. Install the rear engine mounting insulator to the rear engine mounting bracket sub-assembly with the bolt.

      Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

    2. Install the front engine mounting insulator to the front engine mounting bracket with the bolt.

      Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

  18. CONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 21

  19. INSTALL STEERING GEAR HEAT INSULATOR 

    Refer to PROCEDURE - Step 9

  20. INSTALL BREATHER PLUG HOSE 

    Refer to PROCEDURE - Step 23

  21. CONNECT WATER BY-PASS HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 24

  22. INSTALL FLOW SHUTTING VALVE (NO. 1 WATER BY-PASS HOSE) 

    Refer to PROCEDURE - Step 1

  23. CONNECT VACUUM HOSE 

    Refer to PROCEDURE - Step 26

  24. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 

    Refer to PROCEDURE - Step 27

  25. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover to the cylinder block sub-assembly.
  26. INSTALL BOLT 
    1. Install the bolt to the fuel delivery guard.

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

  27. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 

    HINT: 

    Perform "Inspection After Repair" after replacing the engine assembly.

    Refer to INITIALIZATION [08/2020 - ]

    1. Set the engine assembly with transaxle on an engine lifter.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle level.
      • Do not perform any procedures 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.
    2. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.
    3. Install the fuel pump protector with the 2 bolts.

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

    4. Install the fuel delivery guard to the engine mounting bracket RH with the bolt.

      Torque: 40 N.m (408 kgf/cm, 30 ft.lbf) 

    5. Operate the engine lifter and install the engine assembly with transaxle to the vehicle.
      WARNING:

      Do not raise the engine assembly with transaxle more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

      NOTE:
      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
      • While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.
    6. w/o Suspension Tower Damper:
      1. Install the front bumper extension sub-assembly RH and front bumper extension sub-assembly LH to the front frame assembly and vehicle body with the 4 bolts (A), 2 bolts (B) and 2 bolts (C).
        GTY743956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut

        Bolt (A) 

        Torque: 9.0 N.m (92 kgf/cm, 80 in.lbf) 

        Bolt (B) 

        Torque: 12.5 N.m (127 kgf/cm, 9 ft.lbf) 

        Bolt (C) 

        Torque: 135 N.m (1377 kgf/cm, 100 ft.lbf) 

      2. Install the front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH to the front frame assembly and vehicle body with the 2 bolts (D), 2 bolts (E) and 2 nuts.

        Bolt (D) 

        Torque: 17.5 N.m (178 kgf/cm, 13 ft.lbf) 

        Bolt (E) 

        Torque: 135 N.m (1377 kgf/cm, 100 ft.lbf) 

        Nut 

        Torque: 17.5 N.m (178 kgf/cm, 13 ft.lbf) 

    7. w/ Suspension Tower Damper:
      1. Install the front bumper extension sub-assembly RH and front bumper extension sub-assembly LH to the front frame assembly and vehicle body with the 2 bolts (A), 2 bolts (B) and 2 bolts (C).
        GTY947119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut

        Bolt (A) 

        Torque: 9.0 N.m (92 kgf/cm, 80 in.lbf) 

        Bolt (B) 

        Torque: 12.5 N.m (127 kgf/cm, 9 ft.lbf) 

        Bolt (C) 

        Torque: 135 N.m (1377 kgf/cm, 100 ft.lbf) 

      2. Install the front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH to the front frame assembly and vehicle body with the 2 bolts (D), 2 bolts (E) and 2 nuts.

        Bolt (D) 

        Torque: 17.5 N.m (178 kgf/cm, 13 ft.lbf) 

        Bolt (E) 

        Torque: 135 N.m (1377 kgf/cm, 100 ft.lbf) 

        Nut 

        Torque: 17.5 N.m (178 kgf/cm, 13 ft.lbf) 

    8. Install the rear No. 2 engine mounting insulator to the engine mounting bracket sub-assembly LH with the bolt and nut.

      Torque: 42 N.m (428 kgf/cm, 31 ft.lbf) 

      NOTE:

      While holding the bolt in place, tighten the nut.

    9. Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 3 bolts and nut.

      Bolt 

      Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

      Nut 

      Torque: 42 N.m (428 kgf/cm, 31 ft.lbf) 

    10. Install the body mounting plate with the 6 bolts.

      Torque: 17.5 N.m (178 kgf/cm, 13 ft.lbf) 

    11. Engage the clamp.
  28. INSTALL SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper) 

    Refer to PROCEDURE - Step 1

  29. INSTALL FRONT DRIVE SHAFT ASSEMBLY 

    Refer to INSTALLATION [08/2020 - ]

  30. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 

    Refer to INSTALLATION [08/2020 - ]

  31. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 13

  32. CONNECT NO. 5 WATER BY-PASS HOSE 
    1. Engage the clamp.
    2. Connect the No. 5 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.
  33. CONNECT WIRE HARNESS 
    1. Connect the wire harness to the vehicle body with the bolt.
      GTY766541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt (A) 

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    2. Connect the earth wire to the automatic transaxle assembly with the bolt.

      Bolt (B) 

      Torque: 12.5 N.m (127 kgf/cm, 9 ft.lbf) 

    3. Connect the wire harness to the positive (+) battery terminal with the nut.

      Nut (C) 

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

    4. Engage the 3 clamps.
    5. Engage the claw to install the wire harness to the engine room relay block and junction block assembly.
    6. Connect the 4 connectors.
    7. Install the nut.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    8. Install the relay block cover to the engine room relay block and junction block assembly.
  34. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 4

  35. CONNECT SUCTION HOSE 

    Refer to PROCEDURE - Step 3

  36. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the water inlet with thermostat sub-assembly and slide the clip to secure it.
  37. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.
    2. Engage the clamp to connect the No. 1 radiator hose to the No. 1 radiator bracket.
  38. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube sub-assembly.
      1. Connect the fuel tube sub-assembly to the fuel pipe.

        Refer to PRECAUTION [08/2020 - ]

    2. Install the EFI fuel pipe clamp to the fuel tube connector.
  39. CONNECT INLET HEATER WATER HOSE 
    1. Align the protrusions of the inlet heater water hose connector with the cutouts in the flow shutting valve (water by-pass hose assembly) and push them together until the inlet heater water hose connector makes a "click" sound.
      GTY767363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Push in the retainer.
      GTY948591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Push
      Push in
    3. Check that the flow shutting valve (water by-pass hose assembly) and inlet heater water hose connector are securely connected by pulling on them.
  40. CONNECT OUTLET HEATER WATER HOSE 
    1. Align the protrusion of the No. 2 water by-pass pipe sub-assembly with the cutout in the outlet heater water hose connector and push them together until the outlet heater water hose connector makes a "click" sound.
      GTY765348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Push in the retainer.
      GTY948799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Push
      Push in
    3. Check that the No. 2 water by-pass pipe sub-assembly and outlet heater water hose connector are securely connected by pulling on them.
  41. CONNECT UNION TO CHECK VALVE HOSE 
    1. Connect the union to check valve hose to the vacuum pump assembly and slide the clip to secure it.
  42. 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.
  43. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.
    2. Connect the transmission control cable assembly to the transmission control shaft lever as shown in the illustration.
      NOTE:

      Before installing the transmission control cable assembly, check that the park/neutral position switch assembly and shift lever are in N.

      GTY753629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct
      *b Incorrect
  44. INSTALL BATTERY CLAMP SUB-ASSEMBLY 
    1. Install the battery clamp sub-assembly with the 3 bolts.

      Torque: 18.5 N.m (189 kgf/cm, 14 ft.lbf) 

    2. Engage the 4 clamps.
  45. INSTALL BATTERY 

    Refer to PROCEDURE - Step 1

  46. INSTALL ECM 

    Refer to PROCEDURE - Step 3

  47. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 
    1. Install the air cleaner assembly with air cleaner hose to the throttle body with motor assembly and unlock the hose clip to secure it as shown in the illustration.
      NOTE:

      Align the cutout of the air cleaner hose with the protrusion of the throttle body with motor assembly.

      GTY763844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
      *c Top
      *d Front of Vehicle
      *e Locked
      *f Unlocked
    2. Connect the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.
      GTY765418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Top
      *b Front of Vehicle
      *c 45°(Claw of Clip Location)
      *d Paint Mark
      NOTE:

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

    3. Insert the 3 pins of the air cleaner assembly into the 3 air cleaner supports as shown in the illustration.
      GTY948802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Air Cleaner Support
      NOTE:
      • Insert the 3 pins of the air cleaner assembly into the 3 air cleaner supports at the same time.
      • Check that the pins are securely inserted into air cleaner supports.
    4. Engage the vacuum hose to the air cleaner hose.
    5. Engage the 3 wire harness clamps.
    6. Connect the mass air flow meter sub-assembly connector.
  48. INSTALL INLET AIR CLEANER ASSEMBLY 
    1. Install the inlet air cleaner assembly with the 2 bolts in the order shown in the illustration.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

      Fig 1: Inlet Air Cleaner Bolts Tightening Sequence [08/2021 - ]
      GTY752045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Engage the 4 clips to install the No. 1 engine cover sub-assembly.
      GTY1084845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Make sure that the clips are engaged securely.
      • If the clips are forcibly engaged or struck with an object, they may be damaged.
  50. INSPECT VACUUM HOSES 
    1. Inspect the vacuum hoses.
      GTY1084941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2

  52. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 5

  53. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 2

  54. ADD AUTOMATIC TRANSAXLE FLUID 

    Refer to ADJUSTMENT [08/2020 - ]

  55. ADD TRANSFER OIL 

    Refer to PROCEDURE - Step 6

  56. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  57. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  58. INSPECT SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 2 [08/2020 - 09/2022] , or refer to PROCEDURE - Step 2 [09/2022 - ]

  59. ADJUST SHIFT LEVER POSITION 

    Refer to ADJUSTMENT [08/2020 - ]

  60. INSPECT FOR ENGINE OIL LEAK 

    Refer to PROCEDURE - Step 6

  61. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  62. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 5

  63. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  64. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 9

  65. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1 [08/2020 - 07/2023] , or refer to PROCEDURE - Step 1 [07/2023 - ]

  66. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK 

    Refer to PROCEDURE - Step 2

  67. INSPECT FOR TRANSFER OIL LEAK 
  68. INSTALL FRONT LOWER BUMPER ABSORBER 
    1. Engage the 2 claws to install the front lower bumper absorber.
    2. Install the 4 bolts.

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  69. INSTALL FRONT BUMPER COVER 

    Refer to INSTALLATION [08/2021 - 09/2022] , or refer to INSTALLATION [09/2022 - ]

  70. INSTALL FRONT FENDER APRON SEAL LH 
    1. Install the front fender apron seal LH with the 2 screws and clip.

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  71. INSTALL FRONT FENDER APRON SEAL RH 
    1. Install the front fender apron seal RH with the 2 screws and clip.

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  72. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY 
    1. Install the No. 2 engine under cover assembly with the 4 screws and 6 clips.

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  73. INSTALL NO. 1 ENGINE UNDER COVER 
    1. Install the No. 1 engine under cover with the bolt, 6 screws and 2 clips.

      Bolt 

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  74. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 
    1. Install the front wheel opening extension pad LH with the 3 screws.
  75. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 
    1. Install the front wheel opening extension pad RH with the 3 screws.
  76. INSTALL FRONT WHEELS 

    Refer to INSTALLATION [06/2018 - ]

  77. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  78. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [08/2021 - ]

  79. PERFORM INITIALIZATION 

    Refer to PROCEDURE - Step 7

  80. INSPECT IGNITION TIMING 

    Refer to PROCEDURE - Step 9

  81. INSPECT ENGINE IDLE SPEED 

    Refer to PROCEDURE - Step 10

  82. INSPECT CO/HC 

    Refer to PROCEDURE - Step 12

  83. CHECK SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [08/2020 - ]

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