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Home >> Lexus >> 2016 >> LS 600h >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Intake System - Service Information >> Intake Manifold >> Installation [09/2015 - ] >> Procedure

Installation [09/2015 - ]: Procedure

  1. INSTALL INTAKE MANIFOLD 
    1. Install 2 new gaskets to the intake manifold.
    2. Temporarily Install the intake manifold with the 8 bolts and 2 nuts.
    3. Uniformly tighten the bolts and nuts in the order shown in the illustration.

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

      Fig 1: Intake Manifold Tightening sequence
      GTY148304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. CONNECT PCV HOSE 
    GTY148286Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT: 

    Make sure the direction of the hose clamp is as shown in the illustration.

  3. INSTALL PURGE VSV 
    GTY130732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the purge VSV with the bolt.

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

    2. Connect the 2 purge line hoses.

      HINT: 

      Make sure the direction of the hose clamp is as shown in the illustration.

    3. Connect the purge VSV connector.
  4. INSTALL WATER BY-PASS PIPE HOSE 
    GTY134774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the water by-pass pipe hose with the 2 bolts.

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

    2. Connect the 4 water hoses.

      HINT: 

      Make sure the direction of the hose clamp is as shown in the illustration.

  5. INSTALL NO. 3 ENGINE COVER SUB-ASSEMBLY 
    1. Install the No. 3 engine cover sub-assembly with the 2 clips.
      GTY631984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL ENGINE MOTOR CABLE CLAMP BRACKET 
    1. Install the engine motor cable clamp bracket with the bolt.
      GTY641133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Connect the wire harness clamp to the bracket.
  7. INSTALL FLEXIBLE HOSE BRACKET SUB-ASSEMBLY 
    1. Install the flexible hose bracket sub-assembly with the bolt.
      GTY633697Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Connect the flexible hose to the bracket.
  8. INSTALL INJECTOR DRIVER 
    1. Install the No. 1 engine cover to the intake manifold.
    2. Install the injector driver with the 2 bolts and 2 nuts.
      Fig 2: Injector Driver Tightening Sequence
      GTY648094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Uniformly tighten the bolts and nuts in the order shown in the illustration.

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

    4. Connect the 4 wire harness connectors to the injector driver. Then move the lock lever as shown in the illustration to lock the connectors.
      GTY660904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the 3 wire harness clamps to the bracket.
  9. CONNECT ENGINE WIRE HARNESS 
    1. Connect the engine wire harness protector to the intake manifold with the 4 nuts.

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

    2. Connect the 3 wire harness brackets with the 3 bolts.

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

    3. Connect the 4 ground cables with the 4 bolts.

      for timing chain cover 

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

      for engine room RH side 

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

    4. Connect the 3 engine wire harness clamps labeled B.
    5. Attach the 4 engine wire harness clamps labeled A.
    6. Connect the engine wire harness connectors.

      HINT: 

      Connect the 4 wire harness connectors to the injector driver. Then move the lock lever as shown in the illustration to lock the connectors.

      GTY636639Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT ECM CONNECTOR 
    1. Connect the engine wire harness to the ECM box and connect the 4 ECM connectors.
      GTY685737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 2 CONNECTOR HOLDER 
    1. Attach the No. 2 connector holder.
      GTY635095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the wire harness clamp A to the ECM box.
    3. Connect the 3 connectors.
  12. CONNECT HYBRID VEHICLE CONTROL ECU CONNECTOR 
    1. Connect the connector to the hybrid vehicle control ECU.
      GTY677166Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL OUTLET ENGINE ROOM ECM DUCT 

    Refer to PROCEDURE - Step 47

  14. INSTALL ENGINE ROOM ECU COVER 

    Refer to PROCEDURE - Step 4

  15. INSTALL NO. 6 COVER SUB-ASSEMBLY 
    1. Install the No. 6 cover sub-assembly.
      GTY663610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL ENGINE COVER SUB-ASSEMBLY LH 
    1. Install the engine cover sub-assembly LH with the 4 nuts.

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

  17. INSTALL SKID CONTROL ECU BRACKET 

    (Refer to PROCEDURE - Step 1 )

  18. INSTALL AIR CLEANER ASSEMBLY RH 

    Refer to  2

  19. INSTALL AIR CLEANER ASSEMBLY LH 

    Refer to  1

  20. INSTALL THROTTLE BODY ASSEMBLY 

    (Refer to INSTALLATION [09/2015 - ] )

  21. INSTALL SERVICE PLUG GRIP 

    (Refer to INSTALLATION [09/2015 - ] )

  22. 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 [09/2015 - ] ).

  23. INSTALL BATTERY SERVICE HOLE COVER LH 

    Refer to PROCEDURE - Step 13

  24. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 14

  25. INSTALL ENGINE ROOM SIDE COVER LH 

    Refer to PROCEDURE - Step 25

  26. INSTALL ENGINE ROOM SIDE COVER RH 

    Refer to PROCEDURE - Step 26

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