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Home >> Lexus >> 2020 >> UX 200 Luxury >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (M20A-FKS) (Service Information) >> Engine Assembly >> Installation [08/2021 - 07/2022] >> Procedure

Installation [08/2021 - 07/2022]: Procedure

  1. INSTALL ENGINE HANGER 

    See step  40

  2. REMOVE ENGINE FROM ENGINE STAND 
    1. Remove the engine assembly from the engine stand.
  3. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY 

    Refer to PROCEDURE - Step 2

  4. INSTALL GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  5. INSTALL FAN AND GENERATOR V BELT 

    Refer to PROCEDURE - Step 1

  6. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  3

  7. INSTALL ENGINE ASSEMBLY 

    Refer to PROCEDURE - Step 10

  8. CONNECT WATER BY-PASS HOSE ASSEMBLY 
    1. Connect the water by-pass hose assembly to the No. 2 water by-pass pipe sub-assembly and slide the hose clip to secure it.
  9. CONNECT WATER INLET HOSE 
    1. Connect the water inlet hose to the No. 2 water by-pass pipe and slide the hose clip to secure it.
  10. INSTALL ENGINE WIRE 
    1. Connect all the connectors and clamps, and install the engine wire to the engine assembly with transaxle.
    2. Install the 2 bolts.
      GTY801317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Install the bolt.
      GTY801323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    4. Install the 3 bolts.
      GTY832999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    5. Install the bolt and 2 nuts.
      GTY801325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    6. Install the 3 bolts.
      GTY801324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  11. INSTALL FLYWHEEL HOUSING SIDE COVER 
    1. Install the flywheel housing side cover to the cylinder block sub-assembly.
      GTY800671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  13. 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. Temporarily install the engine mounting insulator sub-assembly RH to the vehicle.
      Fig 1: Engine Mounting Insulator Sub-Assembly RH Bolts Tightening Sequence [08/2021 - 07/2022]
      GTY784731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporarily Tighten
    2. Install the 2 bolts and nut in the order shown in the illustration.

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

    3. Connect the air conditioner tube and accessory assembly with the bolt.

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

    4. Install the No. 2 earth wire to the engine mounting insulator sub-assembly RH and vehicle with the 2 bolts.

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

  14. INSTALL ENGINE MOUNTING INSULATOR LH 

    HINT: 

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

    1. Temporarily install the engine mounting insulator LH to the vehicle.
      Fig 2: Engine Mounting Insulator LH Bolts Tightening Sequence [08/2021 - 07/2022]
      GTY1084853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporarily Tighten
    2. Install the 4 bolts and nut in the order shown in the illustration.

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

  15. REMOVE ENGINE HANGER 

    See step  54

  16. INSTALL FUEL DELIVERY GUARD 
    1. Install the fuel delivery guard to the engine mounting bracket RH with the bolt.

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

  17. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front suspension crossmember sub-assembly level, set an engine lifter underneath the engine assembly with transaxle and front suspension crossmember sub-assembly.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle horizontal.
      • 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.
      • 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 transaxle.
    2. 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.
    3. Connect the front suspension crossmember sub-assembly to the vehicle with the 6 bolts.

      Torque: 141 N.m (1438 kgf/cm, 104 ft.lbf) 

    4. Install the engine mounting insulator LH to the engine mounting bracket LH with the through bolt and nut.

      Torque: 44 N.m (449 kgf/cm, 32 ft.lbf) 

      NOTE:

      While holding the nut in place, tighten the through bolt.

    5. Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 2 bolts and nut.

      Bolt 

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

      Nut 

      Torque: 41 N.m (418 kgf/cm, 30 ft.lbf) 

  18. INSTALL NO. 1 SIDE RAIL REINFORCEMENT LH 

    Refer to PROCEDURE - Step 18

  19. INSTALL NO. 1 SIDE RAIL REINFORCEMENT RH 

    HINT: 

    Use the same procedure as for the LH side.

  20. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 

    Refer to PROCEDURE - Step 20

  21. INSTALL FLYWHEEL HOUSING UNDER COVER 

    Refer to PROCEDURE - Step 21

  22. INSTALL DRIVE SHAFT ASSEMBLY 

    Refer to INSTALLATION [10/2018 - 07/2022]

  23. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 

    Refer to INSTALLATION [10/2018 - 07/2022]

  24. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  25. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 21

  26. INSTALL COLUMN HOLE COVER SILENCER SHEET 

    Refer to PROCEDURE - Step 9

  27. CONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  28. CONNECT DISCHARGE HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  29. CONNECT NO. 2 WATER BY-PASS HOSE 
    1. Connect the No. 2 water by-pass hose to the No. 2 water by-pass pipe assembly and slide the hose clip to secure it.
  30. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube sub-assembly to the fuel pump assembly.

      Refer to PRECAUTION [10/2018 - 07/2022]

    2. Engage the clamp to connect the fuel tube sub-assembly.
  31. CONNECT OUTLET HEATER WATER HOSE 
    1. Align the protrusions of the outlet heater water hose connector with the cutouts in the flow shutting valve (water by-pass hose assembly) and push them together until the outlet heater water hose connector makes a "click" sound.
      GTY767363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Push in the retainer.
      GTY816865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Push
      Push in
    3. Check that the flow shutting valve (water by-pass hose assembly) and outlet heater water hose connector are securely connected by pulling on them.
  32. CONNECT INLET HEATER WATER HOSE 
    1. Align the protrusion of the No. 2 water by-pass pipe sub-assembly with the cutout in the inlet heater water hose connector and push them together until the inlet heater water hose makes a "click" sound.
      GTY765348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Push in the retainer.
      GTY821068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Push
      Push in
    3. Check that the No. 2 water by-pass pipe sub-assembly and inlet heater water hose connector are securely connected by pulling on them.
  33. CONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Connect the No. 1 fuel vapor feed hose to the vacuum surge tank and slide the hose clip to secure it.
    2. Engage the clamp to connect the No. 1 fuel vapor feed hose.
  34. CONNECT NO. 1 VACUUM HOSE CONNECTOR 

    Refer to PROCEDURE - Step 3

  35. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the radiator assembly and slide the clip to secure it.
    2. Engage the clamp to connect the No. 2 radiator hose.
  36. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.
  37. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 2

  38. INSTALL BATTERY CLAMP SUB-ASSEMBLY 
    1. Install the battery clamp to the vehicle with the 3 bolts.

      Torque: 15.4 N.m (157 kgf/cm, 11 ft.lbf) 

    2. Engage the clamp to connect the engine wire to the battery clamp.
  39. CONNECT ENGINE WIRE 
    1. Engage the 3 clamps to connect the engine wire to the vehicle.
      GTY832795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the engine wire to the positive (+) auxiliary battery terminal with the 3 nuts.
      GTY801482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Connect the engine wire to the vehicle with the 2 bolts.
      GTY800394Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  40. INSTALL ECM 

    Refer to INSTALLATION [10/2018 - 07/2022]

  41. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Engage the 4 clips to install the No. 1 engine cover sub-assembly.
      GTY819937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Securely engage the clips.
      • If the clips are forcibly engaged or struck with an object, they may be damaged.
  42. INSTALL AUXILIARY BATTERY 

    Refer to INSTALLATION [10/2018 - 07/2022]

  43. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 5

  44. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 3

  45. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID 

    Refer to ADJUSTMENT [10/2019 - 07/2022]

  46. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  47. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  48. INSPECT SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 2

  49. ADJUST SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 17

  50. INSPECT FOR ENGINE OIL LEAK 

    Refer to PROCEDURE - Step 6

  51. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  52. INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK 
  53. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 5

  54. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  55. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 7

  56. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1

  57. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK 

    Refer to PROCEDURE - Step 2

  58. INSTALL REAR ENGINE UNDER COVER LH 
    1. Install the rear engine under cover LH to the vehicle with the 6 clips.
  59. INSTALL REAR ENGINE UNDER COVER RH 
    1. Install the rear engine under cover RH to the vehicle with the 6 clips.
  60. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY 
    1. Install the No. 1 engine under cover assembly to the vehicle with the 4 bolts, 4 screws and 4 clips.

      Bolt 

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

      GTY801884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
  61. INSTALL FRONT WHEELS 

    Refer to PROCEDURE - Step 1

  62. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  63. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [10/2018 - 07/2022]

  64. PERFORM INITIALIZATION 

    Refer to PROCEDURE - Step 8

  65. INSPECT IGNITION TIMING 

    See step  9

  66. INSPECT ENGINE IDLE SPEED 

    See step  10

  67. INSPECT CO/HC 

    See step  12

  68. CHECK SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [10/2018 - 07/2022]

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