LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2016 >> GS 450h Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (Service Information) >> Engine Assembly >> Installation [09/2014 - 10/2015] >> Procedure

Installation [09/2014 - 10/2015]: Procedure

  1. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Install the rear No. 1 engine mounting insulator to the hybrid vehicle transmission assembly with the 4 bolts.
      GTY400453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

      HINT: 

      Make sure that the paint mark faces toward the rear of the vehicle.

      TEXT IN ILLUSTRATION

      *1 Paint Mark
      Rear of Vehicle
  2. INSTALL FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Install the front engine mounting insulator RH and LH with the 2 nuts.

      Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) 

  3. INSTALL ENGINE HANGER 

    See step  77

  4. REMOVE ENGINE STAND 
    1. Attach an engine sling device and hang the engine with a chain block.
      NOTE:

      Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    2. Lift the engine and remove it from the engine stand.
      NOTE:

      With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

    3. Place the engine onto a work bench.
  5. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 
    1. Install the front suspension crossmember sub-assembly with the 2 bolts.

      Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 

  6. INSTALL FAN AND GENERATOR V BELT 

    See step  1

  7. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  8. INSTALL FLYWHEEL SUB-ASSEMBLY 

    See step  2

  9. INSTALL TRANSMISSION INPUT DAMPER COVER ASSEMBLY 

    See step  3

  10. INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY 

    Refer to PROCEDURE - Step 3

  11. INSTALL FLYWHEEL HOUSING SIDE COVER 

    Refer to PROCEDURE - Step 4

  12. INSTALL STARTER HOLE INSULATOR 

    Refer to PROCEDURE - Step 5

  13. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  14. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  15. INSTALL OIL COOLER HOSE TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  16. CONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 15

  17. CONNECT CONNECTOR 

    Refer to PROCEDURE - Step 16

  18. INSTALL REAR ENGINE MOUNTING MEMBER 
    1. Install the engine rear mounting member to the hybrid vehicle transmission assembly with the 4 nuts.

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

  19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 2

  20. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 3

  21. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY LH 
    1. Install the engine under cover sub-assembly LH.
  22. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY RH 
    1. Install the engine under cover sub-assembly RH.
  23. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Install a new O-ring to the engine oil level dipstick guide.
    2. Apply a light coat of engine oil to the O-ring.
    3. Push in the engine oil level dipstick guide end into the guide hole.
    4. Install the engine oil level dipstick guide with the bolt.

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

  24. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 11

  25. INSTALL ENGINE AND TRANSMISSION ASSEMBLY 
    1. Set the engine on an engine lifter.
      NOTE:
      • Place wooden blocks or plate lift attachments so that the engine is level.
      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
      • Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.
    2. Remove the 4 bolts and 2 No. 1 engine hangers.
    3. Operate the engine lifter and install the engine to the vehicle.
      NOTE:

      Make sure that the engine is clear of all wiring and hoses.

    4. Install the engine and transmission assembly with crossmember with the 6 bolts, 4 new bolts and 2 nuts.
      GTY536460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for bolt A 

      Torque: 194 N*m (1978 kgf*cm, 143 ft.*lbf) 

      for bolt B 

      Torque: 50 N*m (510 kgf*cm, 37 ft.*lbf) 

      for bolt C 

      Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf) 

      for nut 

      Torque: 151 N*m (1540 kgf*cm, 111 ft.*lbf) 

      TEXT IN ILLUSTRATION

      Bolt
      Nut
    5. Install the rear engine mounting member with the 4 bolts.

      Torque: 35 N*m (354 kgf*cm, 26 ft.*lbf) 

    6. Connect the wire harness with the nut.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  26. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR 
    1. Install the front lower suspension member protector with the 4 bolts.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

  27. INSTALL FRONT NO. 2 UPPER SUSPENSION MEMBER 
    1. Install the 2 front No. 2 upper suspension members with the 6 bolts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

  28. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  29. CONNECT POWER STEERING LINK WIRE HARNESS 
    1. Connect the wire harness connector (C) to the power steering link assembly and securely lock the connector.
      GTY524379Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Front
    2. Connect the 2 wire harness connectors (A) and (B) to the power steering link assembly.
    3. Connect the 2 wire harness clamps to the bracket.
  30. CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH 

    Refer to PROCEDURE - Step 3

  31. CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH 

    HINT: 

    Install the RH side following the same procedure as for the LH side.

  32. CONNECT FRONT SHOCK ABSORBER ASSEMBLY LH 
    1. Connect the lower part of the front shock absorber assembly LH to the front lower suspension arm assembly with the bolt and nut.

      Torque: 108 N*m (1101 kgf*cm, 80 ft.*lbf) 

      NOTE:
      • Insert the bolt from the rear of the vehicle.
      • When tightening the bolt, keep the nut from rotating.
  33. CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH 

    HINT: 

    Install the RH side following the same procedure as for the LH side.

  34. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  35. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 1

  36. FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING ASSEMBLY 

    Refer to PROCEDURE - Step 2

  37. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE 

    Refer to PROCEDURE - Step 3

  38. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR 

    Refer to PROCEDURE - Step 5

  39. INSTALL NO. 1 FUEL TANK PROTECTOR 

    Refer to PROCEDURE - Step 4

  40. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY 
    1. Install the front center floor brace sub-assembly with the 4 bolts.

      Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) 

  41. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  42. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 3

  43. CONNECT HEATED OXYGEN SENSOR (for Bank 2 Sensor 2) 

    Refer to PROCEDURE - Step 6

  44. CONNECT HEATED OXYGEN SENSOR (for Bank 1 Sensor 2) 

    Refer to PROCEDURE - Step 4

  45. INSTALL FRONT CENTER FLOOR BRACE 

    Refer to PROCEDURE - Step 6

  46. INSTALL NO. 2 REAR FLOOR BOARD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  47. INSTALL NO. 1 REAR FLOOR BOARD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  48. CONNECT ENGINE WIRE 
    1. Engine Room LH Side:
      1. Connect the No. 2 connector holder with the clamp and 3 claws.
      2. Connect the 3 connectors from the No. 2 connector holder.
      3. Install the No. 1 engine room relay block cover.
    2. Engine Room RH Side:
      1. Install the bolt, clamp and No. 3 engine wire.

        Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

  49. CONNECT INVERTER RESERVOIR TANK ASSEMBLY 

    Refer to PROCEDURE - Step 14

  50. CONNECT MOTOR CABLE 

    Refer to PROCEDURE - Step 10

  51. CONNECT GENERATOR CABLE 

    Refer to PROCEDURE - Step 11

  52. INSTALL ECM 

    Refer to PROCEDURE - Step 5

  53. CONNECT SUCTION HOSE 

    Refer to PROCEDURE - Step 4

  54. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 3

  55. INSTALL NO. 1 INVERTER COOLING PIPE 
    1. Install the No. 1 inverter cooling pipe with the bolt.

      Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf) 

    2. Connect the 2 hoses.
    3. Connect the 2 connectors and 2 wire harness clamps.
  56. CONNECT NO. 5 INVERTER COOLING HOSE 
    1. Connect the No. 5 inverter cooling hose.
  57. CONNECT NO. 2 OIL COOLER OUTLET HOSE 

    Refer to PROCEDURE - Step 6

  58. CONNECT NO. 2 OIL COOLER INLET HOSE 

    Refer to PROCEDURE - Step 7

  59. CONNECT AIR CONDITIONING HARNESS 
    1. Connect the white tape part of the air conditioning harness to the clamp as shown in the illustration.
      GTY417760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 White Tape
      *2 Air Conditioning Harness
      NOTE:

      Make sure that the air conditioning harness is securely connected.

    2. Connect the 2 wire harness clamps to each bracket.
    3. Connect the bracket with the bolt.

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

    4. Connect the connector and lock the green-colored lock as shown in the illustration.
      GTY395682Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Green-colored Lock
      WARNING:

      Wear insulated gloves when performing the procedure.

  60. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose.
    2. Install the water hose set.
  61. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose.
    2. Install the water hose set.
  62. CONNECT NO. 2 RADIATOR HOSE 

    Refer to PROCEDURE - Step 3

  63. INSTALL NO. 1 RADIATOR HOSE 

    Refer to PROCEDURE - Step 10

  64. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube sub-assembly (Refer to PRECAUTION [09/2014 - ] ).
  65. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY 
    1. Connect the No. 2 fuel tube sub-assembly (Refer to PRECAUTION [09/2014 - ] ).
  66. CONNECT NO. 3 FUEL TUBE SUB-ASSEMBLY 
    1. Connect the No. 3 fuel tube sub-assembly (Refer to PRECAUTION [09/2014 - ] ).
  67. CONNECT PURGE LINE HOSE 
    1. Install the clamp and connect the purge line hose.
  68. INSTALL HEATER ACCESSORY ASSEMBLY 

    Refer to PROCEDURE - Step 1

  69. CONNECT WIRING HARNESS PROTECTOR 

    Refer to PROCEDURE - Step 4

  70. INSTALL OIL PUMP MOTOR CONTROLLER 

    Refer to PROCEDURE - Step 1

  71. CONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 2

  72. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Insert the pin on the lower side of the air cleaner case into the grommet.
      GTY528158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pin
      *2 Grommet
    2. Install the air cleaner case, 2 clamps and 2 bolts.

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

      NOTE:

      During removal, do not lose the grommet on the underside of the air cleaner case.

  73. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
  74. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 2

  75. INSTALL NO. 1 AIR CLEANER INLET 
    1. Install the No. 1 air cleaner inlet with the bolt.

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

  76. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 5

  77. INSTALL CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 9

  78. INSTALL INVERTER TERMINAL COVER 

    Refer to PROCEDURE - Step 12

  79. INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY 

    Refer to PROCEDURE - Step 13

  80. INSTALL INVERTER COVER 

    Refer to PROCEDURE - Step 20

  81. INSTALL SERVICE PLUG GRIP 

    Refer to PROCEDURE - Step 1

  82. INSTALL LOWER HYBRID VEHICLE BATTERY COVER PANEL 

    Refer to PROCEDURE - Step 2

  83. INSTALL NO. 1 SEAT ARMREST CAP 

    Refer to PROCEDURE - Step 18

  84. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Refer to INITIALIZATION [09/2014 - 10/2015] ).

  85. INSTALL LUGGAGE COMPARTMENT TRIM COVER LH 

    Refer to PROCEDURE - Step 24

  86. INSTALL LUGGAGE COMPARTMENT FLOOR MAT 

    Refer to PROCEDURE - Step 26

  87. PERFORM INITIALIZATION 

    (Refer to INITIALIZATION [09/2014 - 10/2015] )

  88. ADJUST SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 2

  89. INSPECT SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 1

  90. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 5

  91. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 5

  92. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  93. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  94. INSPECT COOLANT LEAK (for Inverter) 

    Refer to PROCEDURE - Step 1

  95. INSPECT FOR OIL LEAK 

    Refer to PROCEDURE - Step 6

  96. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  97. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 9

  98. CHECK FOR REFRIGERANT GAS LEAK 

    Refer to PROCEDURE - Step 4

  99. INSTALL FRONT WHEEL 

    Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 

  100. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  101. CHECK AND ADJUST FRONT WHEEL ALIGNMENT 

    (Refer to ADJUSTMENT [09/2014 - 10/2015] )

  102. ADJUST MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System) 

    Refer to PROCEDURE - Step 1

  103. ADJUST NIGHT VIEW CAMERA ASSEMBLY 

    Refer to PROCEDURE - Step 8

  104. INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY 

    Refer to PROCEDURE - Step 6

  105. INSPECT IGNITION TIMING 

    See step  8

  106. INSPECT ENGINE IDLE SPEED 

    See step  9

  107. INSPECT CO/HC 

    See step  11

  108. INSPECT ENGINE COOLANT LEVEL 

    Refer to PROCEDURE - Step 2

  109. INSPECT COOLANT LEVEL IN RESERVOIR TANK (for Inverter) 

    Refer to PROCEDURE - Step 2

  110. INSPECT ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 2

  111. INSTALL NO. 2 ENGINE UNDER COVER 
    1. Install the No. 2 engine under cover with the 4 screws and 2 grommets.
  112. INSTALL FRONT SUSPENSION MEMBER BRACE 
    1. Install the front suspension member brace with the clip and 4 bolts.

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

  113. INSTALL REAR ENGINE UNDER COVER LH 
    1. Install the rear engine under cover LH with the screw.
  114. INSTALL REAR ENGINE UNDER COVER RH 

    HINT: 

    Install the RH side following the same procedure as for the LH side.

  115. INSTALL ENGINE UNDER COVER 
    1. Install the engine under cover with the 13 screws and 3 clips.
  116. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Attach the 3 clips in the order shown in the illustration to install the V-bank cover.
      GTY526491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Tip (Round Portion)
      NOTE:
      • Securely attach the clips.
      • If the clips are forcibly attached or struck with an object, they may be damaged.
      • Do not apply any oil to the tips (round portions).
  117. INSTALL COOL AIR INTAKE DUCT SEAL 
    1. Install the cool air intake duct seal with the 7 clips.
  118. INSTALL ENGINE ROOM SIDE COVER 
    1. Install the engine room side cover with the 4 clips.
scientia non olet · About LEMON Manuals