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Home >> Lexus >> 2012 >> IS 250C V6-2.5L (4GR-FSE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Installation

Installation





4GR-FSE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. REMOVE ENGINE STAND

(a) Remove the engine assembly from the engine stand.

2. INSTALL FRONT ENGINE MOUNTING INSULATOR LH

(a) Install the front engine mounting insulator LH with the nut.





Torque : 70 Nm (713 kgf-cm, 51 ft-lbf)

HINT
Only perform this procedure when replacement of the engine mounting insulator is necessary.

3. INSTALL FRONT ENGINE MOUNTING INSULATOR RH

(a) Install the front engine mounting insulator RH with the nut.





Torque : 70 Nm (713 kgf-cm, 51 ft-lbf)

4. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Install the front suspension crossmember sub-assembly with the 2 bolts.





Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

5. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) Installation

6. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (for Manual Transmission)

(a) Install the rear No. 1 engine mounting insulator to the manual transmission with the 4 bolts.





Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

HINT
Only perform this procedure when replacement of the engine mounting insulator is necessary.

7. INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission) Installation

8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission) Installation

9. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (for Automatic Transmission)

(a) Install the rear No. 1 engine mounting insulator to the automatic transmission assembly with the 4 bolts.





Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)

HINT
Only perform this procedure when replacement of the engine mounting insulator is necessary.

10. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

(a) Install the automatic transmission assembly for A960E Installation.

11. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission)

(a) Install the drive plate and torque converter clutch setting bolt for A960E Installation.

12. INSTALL FLYWHEEL HOUSING SIDE COVER (for Automatic Transmission)

(a) Install the flywheel housing side cover for A960E Installation.

13. INSTALL STARTER ASSEMBLY Installation

14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Install a new gasket as shown in the illustration.





Text in Illustration





(b) Install the exhaust manifold sub-assembly LH with the 6 nuts.





Text in Illustration





Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

NOTICE:
* Do not damage the stud bolt when installing the exhaust manifold.
* Be sure to tighten either of nuts A first.

15. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Install a new gasket as shown in the illustration.





Text in Illustration





(b) Install the exhaust manifold sub-assembly RH with the 6 nuts.





Text in Illustration





Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

NOTICE:
* Do not damage the stud bolt when installing the exhaust manifold.
* Be sure to tighten either of nuts A first.

16. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY LH

(a) Install the engine under cover sub-assembly LH to the front suspension crossmember sub-assembly with the 2 clips.

17. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY RH

(a) Install the engine under cover sub-assembly RH to the front suspension crossmember sub-assembly with the 2 clips.

18. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Install a new O-ring to the engine oil level dipstick guide.

(b) Apply a light coat of engine oil to the O-ring.

(c) Push the engine oil level dipstick guide end into the guide hole.

(d) Install the engine oil level dipstick guide with the bolt.





Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(e) Connect the clamp.

19. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Install a new O-ring to the No. 2 engine oil level dipstick guide.

(b) Apply a light coat of engine oil to the O-ring.

(c) Push the No. 2 engine oil level dipstick guide end into the engine oil level dipstick guide.

(d) Install the No. 2 engine oil level dipstick guide with the bolt.





Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(e) Install the engine oil level dipstick.

20. INSTALL ENGINE AND TRANSMISSION ASSEMBLY

(a) Set the engine lifter.

(b) Remove the 4 bolts and 2 engine hangers.





Text in Illustration





(c) Operate the engine lifter, then install the engine to the vehicle.

(d) Install the engine and transmission assembly with crossmember with the 12 bolts and 2 nuts.





Text in Illustration





Torque : 167 Nm (1703 kgf-cm, 123 ft-lbf) for Nut

Torque : 204 Nm (2080 kgf-cm, 150 ft-lbf) for bolt A

Torque : 50 Nm (510 kgf-cm, 37 ft-lbf) for bolt B

Torque : 49 Nm (500 kgf-cm, 36 ft-lbf) for bolt C

Torque : 34 Nm (347 kgf-cm, 25 ft-lbf) for bolt D

(e) for Manual Transmission:

(1) Install the rear engine mounting member with the 4 bolts and 4 nuts.





Text in Illustration





Torque : 13 Nm (133 kgf-cm, 10 ft-lbf) for Nut

Torque : 26 Nm (260 kgf-cm, 19 ft-lbf) for Bolt

(f) for Automatic Transmission:

(1) Install the rear engine mounting member with the 4 bolts and 4 nuts.





Text in Illustration





Torque : 13 Nm (133 kgf-cm, 10 ft-lbf) for Nut

Torque : 26 Nm (260 kgf-cm, 19 ft-lbf) for Bolt

(2) Install the ground cable with the nut.





21. CONNECT WATER BY-PASS HOSE (for Automatic Transmission)

(a) Install the 2 water by-pass hoses to the transmission assembly.





Text in Illustration





(b) Install the water by-pass hose clamp with the bolt.

Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)

22. INSTALL WIRE HARNESS (for Automatic Transmission)

(a) Install the wire harness clamps to the automatic transmission assembly with the 2 bolts.





Text in Illustration





Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) Connect the park / neutral position switch connector, transmission wire connector, and 2 transmission revolution sensor connectors.





Text in Illustration





HINT
Push up the lever until the claw of the transmission wire connector makes a connection sound.

23. INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for Automatic Transmission)

(a) Install the floor shift gear shifting rod sub-assembly for A960E Installation.

24. INSTALL FLOOR SHIFT LEVER ASSEMBLY (for Manual Transmission) Installation

25. INSTALL FLOOR SHIFT CONTROL SHIFT LEVER RETAINER SUB-ASSEMBLY (for Manual Transmission) Installation

26. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission) Installation

27. INSTALL NO. 2 CLUTCH HOUSING COVER (for Manual Transmission) Installation

28. INSTALL NO. 1 CLUTCH HOUSING COVER (for Manual Transmission) Installation

29. CONNECT WIRE HARNESS (for Manual Transmission) Installation

30. CONNECT GROUND CABLE (for Manual Transmission) Installation

31. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transmission) Installation

32. INSTALL CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transmission) Installation

33. INSTALL FRONT NO. 6 FLOOR HEAT INSULATOR (for Manual Transmission) Installation

34. CONNECT POWER STEERING LINK WIRE HARNESS

(a) Install the power steering earth wire to the power steering link assembly with bolt (B).





Torque : 13 Nm (130 kgf-cm, 10 ft-lbf)

(b) Connect the wire harness connector (E) to the power steering link assembly and securely lock the connector.

(c) Connect the 2 wire harness connectors (C) and (D) to the power steering link assembly.

(d) Install the 2 wire harness clamps to the power steering link assembly.

(e) Connect the earth wire to the bracket with bolt (A).

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

35. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY (for Automatic Transmission)

(a) Install the No. 1 exhaust pipe support bracket sub-assembly with the 2 bolts.





Text in Illustration





Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

36. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH

(a) Install the front lower ball joint with the 2 bolts.





Torque : 120 Nm (1224 kgf-cm, 89 ft-lbf)

37. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

38. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH

(a) Install the bolt on the lower side of the front shock absorber while holding the nut.





Torque : 157 Nm (1600 kgf-cm, 116 ft-lbf)

39. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

40. CONNECT HEIGHT CONTROL SENSOR LINK (w/ HID Headlight System)

(a) Connect the height control sensor link and install it with the nut.





Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

41. CONNECT STEERING SLIDING YOKE SUB-ASSEMBLY Installation

42. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR

(a) Install the protector with the new 4 bolts.





Torque : 11 Nm (107 kgf-cm, 8 ft-lbf)

43. CONNECT NO. 3 FUEL HOSE

(a) Connect the No. 3 fuel hose and clamp.





44. CONNECT FUEL MAIN TUBE

(a) Observe the following precautions when connecting the fuel tube connectors:

(1) Check that there is no damage or foreign objects on the connector of the pipe.

(2) Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of clean engine oil to the tip of the pipe.





(3) After finishing the connection, check if the pipe and the connector are securely connected by pulling on them.





(4) Check for fuel leaks.

(5) Install the No. 1 fuel pipe clamp.





45. CONNECT ENGINE WIRE

(a) Install the No. 3 engine wire with the bolt and clamp.





Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

(b) Install the ground cable with the bolt.





Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(c) Connect the connector and install the 4 clamps to the body.





(d) Connect the ground cable with the bolt.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

(e) Connect the wire to the No. 1 engine room junction block. Then, install it with the nut.

Torque : 12 Nm (124 kgf-cm, 9 ft-lbf)

(f) Install the engine room No. 1 relay block cover.

(g) Connect the battery positive (+) cable and install it with the nut.

Torque : 7.6 Nm (77 kgf-cm, 69 in-lbf)

(h) Connect the 4 ECM connectors.





(i) Connect the connector holder.





(j) Connect the connector clamp.





(k) Connect the 5 connectors.





46. INSTALL ECM COVER

(a) Install the ECM cover with the 3 bolts.





Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

47. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation

48. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE Installation

49. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose.





50. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose.





51. CONNECT NO. 1 RADIATOR HOSE

(a) Install the clamp and connect the No. 1 radiator hose.





52. CONNECT NO. 2 RADIATOR HOSE

(a) Install the clamp and connect the No. 2 radiator hose.

53. CONNECT RADIATOR RESERVOIR TANK HOSE

(a) Install the clamp and connect the reservoir tank hose.

54. CONNECT NO. 2 FUEL VAPOR FEED HOSE

(a) Install the clamp and connect the No. 2 fuel vapor feed hose.





55. CONNECT UNION TO CHECK VALVE HOSE

(a) Connect the hose to the surge tank.

56. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Install the air cleaner case sub-assembly with the 2 bolts and clamp.





Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

57. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE Installation

58. INSTALL INLET NO. 1 AIR CLEANER

(a) Install the inlet No. 1 air cleaner with the bolt and clip.





Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

59. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for Manual Transmission) Installation

60. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for Automatic Transmission) Installation

61. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

62. INSTALL FRONT CENTER FLOOR BRACE Installation

63. INSTALL REAR BODY SUPPORT BRACKET Installation

64. INSTALL SHIFT LEVER CAP (for Manual Transmission) Installation

65. INSTALL NO. 1 SHIFT AND SELECT LEVER BOOT (for Manual Transmission) Installation

66. INSTALL NO. 2 CONSOLE BOX DUCT (for Manual Transmission) Installation

67. INSTALL CONSOLE BOX (for Manual Transmission) Installation

68. INSTALL CONSOLE BOX REGISTER ASSEMBLY (for Manual Transmission) Installation

69. INSTALL FRONT ASH RECEPTACLE ASSEMBLY (for Manual Transmission) Installation

70. INSTALL FRONT CONSOLE PANEL SUB-ASSEMBLY (for Manual Transmission) Installation

71. INSTALL REAR CONSOLE PANEL SUB-ASSEMBLY (for Manual Transmission) Installation

72. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transmission) Installation

73. ADD ENGINE OIL Replacement

74. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

75. ADD ENGINE COOLANT Service and Repair

76. CHARGE WITH REFRIGERANT Service and Repair

77. INSPECT FOR FUEL LEAK Fuel System

78. INSPECT FOR COOLANT LEAK Testing and Inspection

79. INSPECT FOR OIL LEAK

80. INSPECT FOR EXHAUST GAS LEAK

81. INSPECT FOR REFRIGERANT LEAK Service and Repair

82. INSTALL FRONT WHEEL

Torque : 103 Nm (1,050 kgf-cm, 76 ft-lbf)

83. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

84. INSPECT SHIFT LEVER POSITION (for Automatic Transmission)

(a) Inspect the shift lever position for A960E Initial Inspection and Diagnostic Overview.

85. ADJUST SHIFT LEVER POSITION (for Automatic Transmission)

(a) Adjust the shift lever position for A960E Adjustments.

86. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

HINT
Front Wheel Alignment.

87. INSPECT IGNITION TIMING On-Vehicle Inspection

88. INSPECT ENGINE IDLE SPEED On-Vehicle Inspection

89. INSPECT CO / HC On-Vehicle Inspection

90. INSPECT ENGINE OIL LEVEL Testing and Inspection

91. INSTALL REAR ENGINE UNDER COVER LH

(a) Install the rear engine under cover LH with the bolt.





92. INSTALL REAR ENGINE UNDER COVER RH

HINT
Perform the same procedure as for the LH side.

93. INSTALL NO. 2 ENGINE UNDER COVER

(a) Install the No. 2 engine under cover with the 4 screws.





94. INSTALL NO. 1 BODY MOUNTING BRACKET SUB-ASSEMBLY LH

(a) Install the No. 1 body mounting bracket sub-assembly LH with the 3 bolts.





Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

95. INSTALL NO. 1 BODY MOUNTING BRACKET SUB-ASSEMBLY RH

(a) Install the No. 1 body mounting bracket sub-assembly RH with the 3 bolts.





Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

96. INSTALL NO. 2 FLOOR UNDER COVER

(a) Install the 4 clips and No. 2 floor under cover.





97. INSTALL NO. 1 FLOOR UNDER COVER

(a) Install the 4 clips and No. 1 floor under cover.





98. INSTALL FRONT FLOOR COVER LH

(a) Install the 12 grommets and front floor cover LH.





99. INSTALL FRONT FLOOR COVER RH

(a) Install the 12 grommets and front floor cover RH.





100. INSTALL ENGINE UNDER COVER

101. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Engage the 2 clips on the front of the cover, and then engage the clip on the rear to install the V-bank cover.





NOTICE:
* Be sure to engage the clips securely.
* Do not apply excessive force or hit the cover to engage the clips. This may cause the cover to break.

102. INSTALL ENGINE ROOM SIDE COVER LH

(a) Install the engine room side cover LH with the 4 clips and grommet.





Text in Illustration





103. INSTALL ENGINE ROOM SIDE COVER

(a) Install the engine room side cover with the clip and grommet.





Text in Illustration





104. INSTALL COOL AIR INTAKE DUCT SEAL

(a) Install the intake duct seal with the 11 clips.




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