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HOMESERVICE MANUALSLEXUS2004IS 300 BASE, STANDARDREPAIR AND DIAGNOSISENGINE PERFORMANCEADJUSTMENTENGINE MECHANICALENGINE UNITINSTALLATION

2004 Lexus IS 300 Base, Standard

Engine Unit: Installation

2004 Lexus IS 300 Base, StandardSECTION Installation

A/T: INSTALL DRIVE PLATE
1. Install the front spacer, drive plate and rear plate on the crankshaft.
  
  Fig 1: Installing Drive Plate (A/T)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply adhesive to 2 or 3 threads of the mounting bolt end.
  1. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
3. Install the uniformly tighten the 8 mounting bolts in several passes, in the sequence shown in Fig 2.
  1. Torque: 83 N.m (850 kgf.cm, 61 ft.lbf)
Fig 2: Tightening Mounting Bolts In Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
M/T: INSTALL CLUTCH DISC AND COVER (See INSTALLATION )
A/T: INSTALL TORQUE CONVERTER CLUTCH INSTALLATION (See TORQUE CONVERTER CLUTCH AND DRIVE PLATE )
INSTALL TRANSMISSION TO ENGINE
1. Attach the transmission to the engine.
2. Install the ground wire and 5 bolts.
  1. Torque: 72 N.m (730 kgf.cm, 53 ft.lbf)
Fig 3: Installing Transmission To Engine
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
A/T: CONNECT ENGINE WIRE TO TRANSMISSION
1. Connect the VSS connector.
2. Connect the PNP switch connector.
3. Connect the solenoid connector.
4. Connect the direct clutch speed sensor connector.
5. Connect the engine wire to the 3 wire clamps.
M/T: CONNECT ENGINE WIRE TO TRANSMISSION
1. Connect the VSS connector.
2. Connect the back-up light switch connector.
INSTALL STARTER
1. Install the starter and clamp bracket with the 2 bolts.
  1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
2. Connect the starter connector.
INSTALL 4 BOLTS HOLDING NO. 1 OIL PAN TO TRANSMISSION
1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf)
Fig 4: Installing 4 Bolts Holding No. 1 Oil Pan To Transmission
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
A/T: INSTALL TORQUE CONVERTER CLUTCH BOLTS
1. Apply adhesive to 2 or 3 threads of the bolt end.
  1. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
2. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly.
  1. Torque: 48 N.m (490 kgf.cm, 35 ft.lbf)
  Fig 5: Installing Torque Converter Clutch Bolts (A/T)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  First install the dark green colored bolt, install the other bolts.
3. Install the hole plug.
A/T: INSTALL OIL COOLER PIPE
INSTALL EXHAUST MANIFOLD
1. Install 2 new gaskets to the cylinder head.
2. Using a 14 mm deep socket wrench, install the exhaust manifold with the 8 nuts. Uniformly tighten the nuts in several passes.
  1. Torque: 40 N.m (408 kgf.cm, 30 ft.lbf)
  Fig 6: Installing Exhaust Manifold
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the heated oxygen sensor (bank 2 sensor 1) connector.
4. Install the case clamp.
A/T: INSTALL OIL DIPSTICK GUIDE AND DIPSTICK
1. Install a new O-ring to the dipstick guide.
  
  Fig 7: Installing O-Ring To Dipstick Guide (A/T)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Push in the dipstick guide end to the dipstick tube of the oil pan.
3. Install the dipstick guide with the bolt.
4. Connect the engine wire clamp to the dipstick guide.
5. Install the dipstick.
INSTALL SUSPENSION MEMBER TO ENGINE
Install the suspension member and to the engine with the 4 nuts.
1. Torque: 70 N.m (714 kgf.cm, 52 ft.lbf)
Fig 8: Installing Suspension Member To Engine
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
SET ENGINE JACK
NOTE: Using a chain, hold the engine tightly.