2005 Lexus IS 300 Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Engine Unit: Installation

  1. A/T: 

    INSTALL DRIVE PLATE 

    1. Install the front spacer, drive plate and rear plate on the crankshaft.
      Fig 1: Installing Front Spacer, Drive Plate And Rear Plate On Crankshaft
      G02948699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply adhesive to 2 or 3 threads of the mounting bolt end.

      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.
      1. Torque: 83 N.m (850 kgf.cm, 61 ft.lbf) 
      Fig 2: Identifying Tightening Sequence Of Mounting Bolts
      G02948700Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. M/T: 

    INSTALL CLUTCH DISC AND COVER (See  INSTALLATION  ) 

  3. A/T: 

    INSTALL TORQUE CONVERTER CLUTCH AND DRIVE PLATE (See  TORQUE CONVERTER CLUTCH AND DRIVE PLATE  ) 

  4. 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) 
      3. Fig 3: Installing Transmission To Engine
      G02948701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. 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.
  6. M/T: 

    CONNECT ENGINE WIRE TO TRANSMISSION 

    1. Connect the VSS connector.
    2. Connect the back-up light switch connector.
  7. 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.
  8. INSTALL 4 BOLTS HOLDING NO.1 OIL PAN TO TRANSMISSION 
    1. Torque: 37 N.m (380 kgf.cm, 27 ft.lbf) 
    Fig 4: Installing Bolts Holding No.1 Oil Pan To Transmission
    G02948702Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. A/T: 

    INSTALL TORQUE CONVERTER CLUTCH BOLTS 

    1. Apply adhesive to 2 or 3 threads of the bolt end.

      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) 

      HINT:

      First install the dark green colored bolt, install the other bolts.

      Fig 5: Installing Dark Green Colored Bolt
      G02948703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the hole plug.
  10. A/T: 

    INSTALL OIL COOLER PIPE 

  11. 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 With Nuts
      G02948704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the heated oxygen sensor (bank 2 sensor 1) connector.
    4. Install the case clamp.
  12. A/T: 

    INSTALL OIL DIPSTICK GUIDE AND DIPSTICK 

    1. Install a new O-ring to the dipstick guide.
    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.
      6. Fig 7: Installing Oil Dipstick Guide And Dipstick
      G02948705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. 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 With Nuts
    G02948706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. SET ENGINE JACK 
    NOTE: Using a chain, hold the engine tightly.
  15. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE 
    1. Raise the engine into the engine compartment.
    2. Keep the engine level, and align RH and LH mountings with the insulator.
    Fig 9: Installing Engine And Transmission Assembly In Vehicle
    G02948707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. CONNECT SUSPENSION MEMBER 

    Connect the suspension member with the 4 bolts to the body.

    1. Torque: 70 N.m (714 kgf.cm, 52 ft.lbf) 
    Fig 10: Connecting Suspension Member With Bolts To Body
    G02948708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. CONNECT REAR ENGINE MOUNTING MEMBER 

    Install the rear engine mounting member with the 4 bolts.

    1. Torque: 

      25.5 N.m (260 kgf.cm, 19 ft.lbf) for bolt 

      13.5 N.m (135 kgf.cm 10 ft.lbf) for nut 

    Fig 11: Installing Rear Engine Mounting Member With Bolts
    G02948709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE ENGINE JACK 
  19. CONNECT LOWER ARM 
    1. Connect the lower arm with the 2 bolts to the steering knuckle.
      1. Torque: 245 N.m (2,500 kgf.cm, 181 ft.lbf) 
    2. Connect the height level sensor to the lower arm.
      3. Fig 12: Connecting Lower Arm With Bolts To Steering Knuckle
      G02948710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. CONNECT SHOCK ABSORBER 

    Connect the shock absorber with the bolt and nut.

    1. Torque: 64 N.m (650 kgf.cm, 47 ft.lbf) 
  21. INSTALL STABILIZER BAR 
    1. Install the 2 bushings and 2 stabilizer bar brackets to the stabilizer bar.
    2. Install the stabilizer bar with the 4 bolts and 2 nuts.
      1. Torque: 

        18 N.m (180 kgf.cm, 13 ft.lbf) for bolt 

        49 N.m (500 kgf.cm, 36 ft.lbf) for nut 

      3. Fig 13: Installing Stabilizer Bar
      G02948711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. CONNECT SLIDING YOKE 
    1. Align the matchmarks and connect the sliding yoke to the steering intermediate shaft.
    2. Install the bolt holding the sliding yoke to the steering intermediate shaft.
      1. Torque: 35 N.m (360 kgf.cm, 26 ft.lbf) 
    3. Connect the PS pressure switch and wire clamp.
    Fig 14: Connecting Sliding Yoke
    G02948712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL FRONT AND CENTER EXHAUST PIPE 
    1. Torque: 43 N.m (438 kgf.cm, 32 ft.lbf) 
  24. A/T: 

    INSTALL TRANSMISSION CONTROL ROD 

    Install the control rod with the 2 nuts.

    1. Torque: 16 N.m (163 kgf.cm, 12 ft.lbf) 
    Fig 15: Installing Transmission Control Rod
    G02948713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If the indicator is not aligned with the correct position, carry out the following adjustment procedures.

    1. Loosen the nut on the shift lever.
    2. Push the control shaft lever fully rearward.
    3. Return the control shaft lever 2 notches to the N position.
    4. Set the shift lever to the N position.
    5. While holding the shift lever lightly toward the R position side, tighten the nut.
    6. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) 
      7. Fig 16: Adjusting Indicator
      G02948714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. M/T: 

    INSTALL CLUTCH RELEASE CYLINDER TO TRANSMISSION 

  26. INSTALL A/C COMPRESSOR AND PS PUMP 
    1. Temporarily install the compressor with the 2 bolts.
    2. Using a torx socket (E10), install the stud bolt.
      1. Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) 
      3. Fig 17: Installing Compressor With Bolts
      G02948715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the nut and 2 bolts.
      1. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 
    4. Connect the compressor connector.
    5. Connect the PPS solenoid valve connector.
    6. Install the vane pump assembly with the 3 bolts and plate washer.
      1. Torque: 

        58 N.m (590 kgf.cm, 43 ft.lbf) for bolt A 

        52 N.m (530 kgf.cm, 38 ft.lbf) for bolt B 

      Fig 18: Installing Vane Pump Assembly With Bolts And Plate Washer
      G02948716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Install the pump rear stay with the 2 bolts.
      1. Torque: 39.2 N.m (400 kgf.cm, 29 ft.lbf) 
      Fig 19: Installing Pump Rear Stay With Bolts
      G02948717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the PS air hose to the No. 4 timing belt cover,
    9. Connect the PS air hose to the air intake chamber.
  27. M/T: 

    INSTALL TRANSMISSION SHIFT LEVER 

    1. Install the shift lever with the 4 bolts.
      1. Torque: 8 N.m (82 kgf.cm, 71 in.lbf) 
  28. CONNECT ENGINE WIRE TO ECM BOX 
    1. Install the engine wire grommet to the ECM box.
    2. Connect the 3 ECM connectors.
    3. Connect the 4 wire harness connectors.
    4. Connect the 2 junction connectors.
    5. Install the ECM cover and hood.
    Fig 20: Connecting Engine Wire To ECM Box
    G02948718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. CONNECT CLAMPS, WIRES, CONNECTORS, HOSES, CABLE AND STRAP 
    1. Connect the 2 engine wire clamps to the clamp brackets.
    2. Connect the igniter connector.
    3. Connect the ground cable to the bracket on the cylinder block.
      4. Fig 21: Connecting Ground Cable To Bracket On Cylinder Block
      G02948719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the engine wire clamp to the wire clip of the generator.
    5. Connect the generator wire.
    6. Connect the heated oxygen sensor (bank 1 sensor 1) connector.
    7. Connect the heated oxygen sensor (bank 1 sensor 2) connector.
    8. Connect the EVAP hose to the pipe (from charcoal canister).
      9. Fig 22: Connecting EVAP Hose To Pipe (From Charcoal Canister)
      G02948720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Connect the heater hose to the heater pipe.
    10. Connect the heater hose to the water bypass pipe.
    11. Connect the ground strap to the dash panel.
    12. Connect the fuel inlet hose to the fuel pipe support.
      1. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 
    13. Connect the starter wire to the terminal and manifold stay.
    14. Connect the ground wire to the floor.
  30. INSTALL FRONT SUSPENSION MEMBER BRACE 

    Install the brace with the 8 bolts.

    1. Torque: 

      Bolt A: 119 N.m (1,210 kgf.cm, 88 ft.lbf) 

      Bolt B: 58 N.m (590 kgf.cm, 43 ft.lbf) 

    Fig 23: Installing Brace With Bolts
    G02948721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL DRIVE BELT (See  CHARGING SYSTEM  ) 
  32. M/T: 

    INSTALL DRIVE BELT TENSIONER ABSORBER 

    Install the absorber with the 2 nuts.

    1. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 
  33. CONNECT ACCELERATOR CABLE TO ENGINE 
  34. INSTALL INTAKE AIR RESONATOR 
    1. Connect the intake air resonator to the throttle body.
    2. Tighten the hose clamp bolt holding the intake air resonator to the throttle body.
    3. Connect the MAF meter connector.
    4. Connect the engine wire clamp to the air cleaner case.
    5. Connect the PCV hose to the No.2 cylinder head cover.
    Fig 24: Installing Intake Air Resonator
    G02948722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. CONNECT RADIATOR UPPER AND LOWER HOSES 
  36. CONNECT BRAKE BOOSTER VACUUM HOSE 
  37. INSTALL AIR CLEANER INLET 
  38. INSTALL ENGINE COVER 

    Install the engine cover with the 4 nuts.

  39. FILL WITH ENGINE COOLANT 
  40. FILL WITH ENGINE OIL 
  41. START ENGINE AND CHECK FOR LEAKS 
  42. INSTALL ENGINE UNDER COVER 
    NOTE: Be careful not to damage the body or glass with the hood end.
  43. PERFORM ROAD TEST 

    Check for abnormal noise, shock, slippage, correct shift points and smooth operation.

  44. RECHECK ENGINE COOLANT AND OIL LEVELS 
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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