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Home >> Lexus >> 2016 >> GS 200t Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - Service Information >> Engine Unit >> Installation [10/2015 - ] >> Procedure

Installation [10/2015 - ]: Procedure

  1. INSTALL AIR CLEANER BRACKET 

    Refer to PROCEDURE - Step 10

  2. INSTALL NO. 1 TURBO WATER PIPE 

    Refer to PROCEDURE - Step 13

  3. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 6

  4. INSTALL IDLER PULLEY SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  5. INSTALL OIL FILLER CAP GASKET 
    1. Install the oil filler cap gasket to the oil filler cap sub-assembly.
  6. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
  7. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. for Engine Front Side:
      1. Install the wire harness clamp bracket to the timing chain cover assembly with the bolt.

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

      2. Connect the connector to the oil pressure sender gauge assembly.
    2. for Engine Upper Side:
      1. Install the wire harness clamp bracket to the cylinder head cover sub-assembly with the bolt.

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

    3. for Engine RH Side:
      1. Install the 2 wire harness clamp brackets to the stiffening crankcase assembly with the 2 bolts.

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

    4. for Engine Rear Side:
      1. Install the wire harness clamp bracket to the cylinder head sub-assembly with the bolt.

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

  8. INSTALL SENSOR WIRE 
    1. Install the sensor wire to the fuel delivery pipe sub-assembly with the 2 bolts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    2. Connect the 4 connectors to the direct fuel injector assembly.
    3. Connect the connector to the fuel pressure sensor.
  9. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 5

  10. INSTALL TURBOCHARGER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  11. CONNECT TURBO OIL INLET PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  12. TEMPORARILY INSTALL NO. 1 HEAT INSULATOR BRACKET 

    Refer to PROCEDURE - Step 8

  13. TEMPORARILY INSTALL NO. 2 HEAT INSULATOR BRACKET 

    Refer to PROCEDURE - Step 7

  14. TIGHTEN NO. 1 AND NO. 2 HEAT INSULATOR BRACKET 

    Refer to PROCEDURE - Step 9

  15. INSTALL COMPRESSOR OUTLET ELBOW 
    NOTE:

    Be sure not to disconnect the PCV hose or the No. 4 PCV hose from the cylinder head cover sub-assembly.

    1. Install a new gasket to the turbocharger sub-assembly.
    2. Install the compressor outlet elbow to the turbocharger sub-assembly with the 2 nuts.

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

  16. INSTALL NO. 5 EXHAUST MANIFOLD HEAT INSULATOR 
    NOTE:

    Be sure not to disconnect the PCV hose or the No. 4 PCV hose from the cylinder head cover sub-assembly.

    1. Temporarily install the No. 5 exhaust manifold heat insulator to the compressor outlet elbow and camshaft housing sub-assembly with the 3 bolts labeled A and labeled B.
      GTY671009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt labeled C.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

    3. Tighten the 3 bolts labeled A and labeled B.

      for bolt A 

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

      for bolt B 

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  17. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  18. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 15

  19. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH 
    1. Install the front No. 1 engine mounting bracket RH to the cylinder block sub-assembly with the 4 bolts.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

  20. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH 

    Refer to PROCEDURE - Step 11

  21. INSTALL INTAKE MANIFOLD WITH INTERCOOLER ASSEMBLY AND THROTTLE WITH MOTOR BODY ASSEMBLY 
    1. Install the 2 new No. 1 intake manifold to head gaskets to the intake manifold.
    2. Temporarily install the intake manifold with intercooler assembly and throttle with motor body assembly with the 4 bolts and 2 nuts.
    3. Tighten the 4 bolts and 2 nuts in the sequence shown in the illustration to install the intake manifold with intercooler assembly and throttle with motor body assembly.
      Fig 1: Intake Manifold / Intercooler / Throttle Body Bolts And Nuts Tightening Sequence
      GTY679937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 
    4. Install the wire harness clamp bracket to the intake manifold with the bolt.

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

  22. CONNECT NO. 3 WATER BY-PASS HOSE 
    1. Connect the No. 3 water by-pass hose to the water outlet sub-assembly, and slide the clamp to secure the hose.
    2. Attach the clamp to the engine oil level dipstick guide.
  23. INSTALL NO. 2 PCV HOSE 

    Refer to PROCEDURE - Step 9

  24. CONNECT VACUUM TRANSMITTING HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 10

  25. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 13

  26. INSTALL PURGE VSV 

    Refer to PROCEDURE - Step 1

  27. INSTALL WATER BY-PASS PIPE ASSEMBLY 
    1. Install the water by-pass pipe assembly to the intercooler assembly and No. 2 air tube with the 2 bolts.

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

    2. Connect the No. 9 water by-pass hose to the intercooler assembly, and slide the clamp to secure the hose.
    3. Connect the No. 2 turbo water hose to the No. 1 turbo water pipe, and slide the clamp to secure the hose.
  28. INSTALL NO. 2 WATER BY-PASS PIPE 

    Refer to PROCEDURE - Step 2

  29. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET 

    Refer to PROCEDURE - Step 6

  30. INSTALL COOLER COMPRESSOR ASSEMBLY 

    Refer to PROCEDURE - Step 3

  31. INSTALL GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

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