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Home >> Lexus >> 2023 >> ES 300h Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical System (A25A-FXS) - Service Information (3 Of 3) >> Engine Unit >> Installation [06/2018 - 08/2021] >> Procedure

Installation [06/2018 - 08/2021]: Procedure

  1. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Type A:
      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) 

    2. Type B:
      1. Install the No. 3 exhaust manifold heat insulator to the cylinder block sub-assembly with the 2 bolts.

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

  2. 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.
  3. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  4. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  5. INSTALL FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 3

  6. INSTALL PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  7. INSTALL NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 2

  8. INSTALL INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 3

  9. INSTALL NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 4

  10. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  11. 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) 

  12. 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.
  13. 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.
  14. INSTALL NO. 7 WATER BY-PASS HOSE 
    1. Install the No. 7 water by-pass hose and slide the 2 clips to secure it.
  15. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 1

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

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 3

  18. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. for EGR Valve Bracket Connection Type:
      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.
        GTY742679Courtesy 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)
    2. for Cylinder Head Cover Sub-assembly Connection Type:
      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.

        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)
        GTY947610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 17 mm Union Nut Wrench
        *b Torque Wrench Fulcrum Length
      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) 

  19. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  20. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 3

  21. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 4

  22. 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).
      GTY768411Courtesy 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) 

  23. INSTALL NO. 3 WATER BY-PASS PIPE 
    1. Connect 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, install the No. 3 water by-pass pipe to the intake manifold with the bolt.

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

  24. INSTALL EGR VALVE ASSEMBLY 
    1. Using an 8 mm socket wrench, install the EGR valve bracket with the bolt.

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

    2. for EGR Valve Bracket Connection Type:
      1. Align and fit the hole of the EGR valve bracket to the pin of the camshaft housing sub-assembly.
        GTY759336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Pin
        *b Hole
      2. Using an 8 mm socket wrench, install the EGR valve assembly with the EGR valve bracket to the camshaft housing sub-assembly with the bolt.

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

      3. Using an 8 mm socket wrench, connect the No. 1 fuel pipe sub-assembly to the EGR valve bracket with the bolt.

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

    3. for Cylinder Head Cover Sub-assembly Connection Type:
      1. Align and fit the hole of the EGR valve bracket to the pin of the camshaft housing sub-assembly.
        GTY948317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Pin
        *b Hole
      2. Using an 8 mm socket wrench, install the EGR valve assembly with the EGR valve bracket to the camshaft housing sub-assembly with the bolt.

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

    4. Connect the No. 8 water by-pass hose to the EGR valve assembly and slide the clip to secure it.
  25. INSTALL NO. 4 WATER BY-PASS HOSE 
    1. Install the No. 4 water by-pass hose to the EGR valve assembly and slide the clip to secure it.
  26. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  27. INSTALL EGR COOLER ASSEMBLY 
    1. Install the EGR cooler assembly, a new EGR cooler gasket and EGR valve gasket with the 5 bolts.

      Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

    2. Connect the No. 3 water by-pass hose to the EGR cooler assembly and slide the clip to secure it.
    3. Connect the No. 4 water by-pass hose to the EGR cooler assembly and slide the clip to secure it.
  28. INSTALL THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 1

  29. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  30. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 2

  31. INSTALL MANIFOLD STAY 

    Refer to PROCEDURE - Step 3

  32. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Type A:
      1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 5 bolts.

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

    2. Type B:
      1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 3 bolts.

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

  33. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY) 
    1. Install the water hose clamp bracket with the 2 bolts as shown in the illustration.

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

      GTY793843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    2. Connect the flow shutting valve (water by-pass hose assembly) to the water by-pass outlet sub-assembly and slide the clip to secure it.
      GTY752878Courtesy 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 water by-pass outlet sub-assembly.
      • Make sure that the claws of the clip are within the location shown in the illustration.
    3. Install the flow shutting valve (water by-pass hose assembly) with the bolt.

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

  34. 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.
  35. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 
    1. Using an E8 "TORX" socket wrench, temporarily install the compressor with motor assembly with the 2 stud bolts.

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

    2. Install the compressor with motor assembly with the bolt and 2 nuts.
      Fig 1: Compressor With Motor Assembly Bolt And Nuts Tightening Sequence [06/2018 - 08/2021]
      GTY769374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

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

      HINT: 

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

  36. 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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