LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2020 >> GX 460 Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (Service Information) >> Engine Assembly >> Installation [08/2015 - 08/2020] >> Procedure

Installation [08/2015 - 08/2020]: Procedure

  1. INSTALL ENGINE HANGER 

    See step  75

  2. REMOVE ENGINE STAND 
    1. Attach an engine sling device and hang the engine assembly with a chain block.
      GTY629860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Engine Hanger
      *2 Engine Assembly
      *a 50° or less
    2. Lift the engine assembly and remove it from the engine stand.
    3. Place the engine assembly onto a workbench.
  3. INSTALL NO. 1 WATER BY-PASS PIPE 
    1. Connect the 2 water by-pass hoses to the No. 4 water by-pass pipe and No. 2 water by-pass pipe, and slide the 2 clamps to secure the hose and install the No. 1 water by-pass pipe.
      GTY662191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Upper Side
      *b RH Side
      *c Paint Mark

      HINT: 

      • When connecting the water by-pass hoses, make sure the paint marks and clamps are as shown in the illustration.
      • The direction of the hose clamp is indicated in the illustration.
  4. INSTALL ENGINE ASSEMBLY 

    HINT: 

    Perform "Inspection After Repairs" after replacing the engine assembly (Refer to INITIALIZATION [08/2015 - ] ).

    1. Attach an engine sling device and hang the engine assembly with a chain block.
    2. Slowly lower the engine assembly into the engine compartment.
    3. Install the front engine mounting insulator LH and RH with the 2 nuts and 4 bolts.

      for nut 

      Torque: 72 N*m (734 kgf*cm, 53 ft.*lbf) 

      for bolt 

      Torque: 57 N*m (581 kgf*cm, 42 ft.*lbf) 

      GTY682036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Bolt
      Nut
    4. Remove the 2 bolts and 2 engine hangers.
  5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 
    1. Using SST, hold the crankshaft.
      • SST: 09213-70011 
        1. 09213-70020
      • SST: 09330-00021 
    2. Install the crankshaft angle sensor rotor.
      GTY287705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Engine Side

      HINT: 

      • Align the pin hole of the crankshaft angle sensor rotor with the pin of the crankshaft.
      • As the crankshaft angle sensor rotor is not reversible, be sure to install it so that it is facing in the direction shown in the illustration.
    3. Install the drive plate and ring gear sub-assembly and the rear drive plate spacer to the crankshaft.
      GTY281788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Drive Plate and Ring Gear Sub-assembly
      *2 Rear Drive Plate Spacer
      Transmission Assembly Side

      HINT: 

      As the rear drive plate spacer and the drive plate and ring gear sub-assembly are not reversible, be sure to install them so that they are facing in the directions shown in the illustration.

    4. Install the drive plate and ring gear sub-assembly and bolts.

      HINT: 

      The bolts are tightened in 2 progressive steps.

      1. Clean the bolts and bolt holes.
      2. Apply adhesive to 2 or 3 threads at the end of each of the 10 bolts.
        GTY479398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Adhesive

        Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

        TEXT IN ILLUSTRATION

        *a Adhesive
      3. Step 1:

        Uniformly install and tighten the 10 new bolts in several steps in the sequence shown in the illustration.

        Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) 

        Fig 1: Drive Plate Installation Bolt Tightening Sequence With Torque Specifications
        GTY670882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Mark the top of each drive plate installation bolt with paint.
      5. Step 2:

        Tighten the drive plate installation bolts 90°.

      6. Check that the painted marks are now at a 90° angle to the top.
        NOTE:

        Do not start the engine for at least an hour after installing the drive plate and ring gear sub-assembly.

  6. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.

    1. Install the rear No. 1 engine mounting insulator to the transfer with the 4 bolts.

      Torque: 72.5 N*m (739 kgf*cm, 53 ft.*lbf) 

    2. Install the rear engine mounting heat insulator to the rear No. 1 engine mounting insulator with the bolt.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

  7. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY 

    (Refer to INSTALLATION [08/2015 - ] )

  8. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT 

    Refer to PROCEDURE - Step 12

  9. INSTALL PROPELLER SHAFT ASSEMBLY 

    (Refer to INSTALLATION [08/2015 - ] )

  10. INSTALL FRONT PROPELLER SHAFT ASSEMBLY 

    (Refer to INSTALLATION [08/2015 - ] )

  11. CONNECT OIL COOLER TUBE SUB-ASSEMBLY 
    1. Connect the oil cooler tube sub-assembly with the bolt.

      Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) 

  12. CONNECT ENGINE WIRE 
    1. Connect the ECM connector.
      1. Attach the wire harness clamp.
      2. Attach the grommet to the wire harness support.
        GTY664270Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Grommet
        *2 Wire Harness Support
      3. Pass the wire harness into the vehicle and install the wire harness support.
      4. Connect the 6 connectors and attach the clamp.
        GTY627492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the lower instrument panel (Refer to PROCEDURE - Step 28 [08/2015 - 08/2019] , or refer to PROCEDURE - Step 27 [08/2019 - 08/2021] ).
    3. for Engine Room RH Side:
      1. Attach the 3 wire harness clamps to connect the engine wire and connect the connector.
        GTY645203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Engine Wire
        *2 Ground Wire
      2. Connect the ground wire with the bolt.

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

    4. for Engine Room LH Side:
      1. Attach the wire harness clamp.
        GTY679200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 No. 2 Engine Wire
        *2 Ground Wire
      2. Connect the No. 2 engine wire and ground wire with the 2 bolts.

        for bolt A 

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

        for bolt B 

        Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

      3. Attach the 2 claws and connect the engine wire to the engine room relay block.
        GTY258257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 Engine Wire
        *2 Engine Room Relay Block
      4. Install the nut to the engine room relay block.

        Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) 

      5. Connect the connector.
      6. Connect the ground wire with the bolt.

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

        GTY655845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. CONNECT FUEL HOSE AND NO. 2 FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel hose and No. 2 fuel tube sub-assembly (Refer to PRECAUTION [08/2015 - ] ).
    2. Install the 2 fuel pipe clamps to the fuel tube connector.
  14. INSTALL FLYWHEEL HOUSING SIDE COVER 
  15. INSTALL STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 2

  16. INSTALL STARTER COVER 

    Refer to PROCEDURE - Step 3

  17. INSTALL EXHAUST MANIFOLD ASSEMBLY RH 

    Refer to PROCEDURE - Step 3

  18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 4

  19. INSTALL EXHAUST MANIFOLD ASSEMBLY LH 

    Refer to PROCEDURE - Step 5

  20. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 6

  21. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  22. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 15

  23. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 10

  24. INSTALL FRONT NO. 2 EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 11

  25. INSTALL EXHAUST PIPE STOPPER BRACKET 

    Refer to PROCEDURE - Step 12

  26. INSTALL COOLER COMPRESSOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  27. INSTALL SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the attached vinyl tape from the suction hose sub-assembly.
    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler compressor assembly.

      Compressor oil

      ND-OIL 8 or equivalent

    3. Install the 2 O-rings to the suction hose sub-assembly.
    4. Install the suction hose sub-assembly with the 2 bolts and nut.

      for bolt A 

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      for bolt B and nut 

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      GTY640124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL DISCHARGE HOSE SUB-ASSEMBLY 
    1. Remove the attached vinyl tape from the discharge hose sub-assembly.
    2. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler compressor assembly.

      Compressor oil

      ND-OIL 8 or equivalent

    3. Install the 2 O-rings to the discharge hose sub-assembly.
    4. Install the discharge hose sub-assembly with the 3 bolts.

      for bolt A 

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

      for bolt B 

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

      for bolt C 

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

      GTY618935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. INSTALL GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  30. INSTALL VANE PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  31. CONNECT PRESSURE FEED TUBE 

    Refer to PROCEDURE - Step 2

  32. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE 

    Refer to PROCEDURE - Step 4

  33. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 9

  34. INSTALL AIR TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 10

  35. INSTALL VENTILATION HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 12

  36. CONNECT NO. 4 WATER BY-PASS PIPE 

    Refer to PROCEDURE - Step 13

  37. INSTALL EGR VALVE BRACKET 

    Refer to PROCEDURE - Step 1

  38. INSTALL EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 4

  39. CONNECT NO. 13 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 5

  40. CONNECT NO. 12 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 6

  41. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY (for Single Air Conditioning System) 
    GTY661971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    TEXT IN ILLUSTRATION

    *a Upper Side *b LH Side
    *c Rear *d Paint Mark
    1. Install the water pipe and hose sub-assembly with the 2 nuts.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

    2. Connect the 4 water hoses to the water pipe, and slide the 4 clamps to secure the hose.

      HINT: 

      • When connecting the water hoses, make sure the paint marks and clamps are as shown in the illustration.
      • The direction of each hose clamp is indicated in the illustration.
  42. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY (for Dual Air Conditioning System) 
    GTY624282Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    TEXT IN ILLUSTRATION

    *a Upper Side *b LH Side
    *c Rear *d Paint Mark
    1. Install the water pipe and hose sub-assembly with the 2 nuts.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

    2. Connect the 6 water hoses to the water pipe, and slide the 6 clamps to secure the hose.

      HINT: 

      • When connecting the water hoses, make sure the paint marks and clamps are as shown in the illustration.
      • The direction of each hose clamp is indicated in the illustration.
  43. INSTALL RADIATOR ASSEMBLY 

    Refer to PROCEDURE - Step 7

  44. CONNECT OIL COOLER ACCESSORY ASSEMBLY 

    Refer to PROCEDURE - Step 8

  45. INSTALL NO. 2 RADIATOR HOSE 

    Refer to PROCEDURE - Step 9

  46. INSTALL FAN SHROUD 

    Refer to PROCEDURE - Step 10

  47. INSTALL NO. 1 RADIATOR HOSE 

    Refer to PROCEDURE - Step 11

  48. INSTALL RADIATOR RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 12

  49. INSTALL RADIATOR SIDE DEFLECTOR RH 

    Refer to PROCEDURE - Step 13

  50. INSTALL RADIATOR SIDE DEFLECTOR LH 

    Refer to PROCEDURE - Step 14

  51. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Install the air cleaner case sub-assembly with the 3 bolts.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

  52. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
  53. INSTALL AIR CLEANER CAP AND HOSE 
    1. Attach the 4 clamps to install the air cleaner cap and hose.
      GTY456507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Air Cleaner Hose
      *2 Throttle Body Assembly
      *a Upper Side
      *b Front
      *c Groove
      *d Protrusion

      HINT: 

      When installing the air cleaner hose, align its groove with the protrusion of the throttle body assembly as shown in the illustration.

    2. Tighten the hose clamp.

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

      HINT: 

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

    3. Connect the mass air flow meter connector and No. 1 air hose and attach the wire harness clamp.
    4. Connect the No. 2 ventilation hose to the air cleaner hose, and slide the clamp the secure the hose.
  54. INSTALL FRONT BUMPER COVER 

    (Refer to PROCEDURE - Step 16 [08/2015 - 08/2019] , or refer to PROCEDURE - Step 16 [08/2019 - ] )

  55. INSTALL BATTERY TRAY 
  56. INSTALL BATTERY 
    1. Install the battery.
    2. Install the battery hold down clamp with the 2 nuts.

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

    3. Install the No. 2 engine wire with the nut.

      Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf) 

  57. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    (Refer to PROCEDURE - Step 4 )

  58. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Refer to INITIALIZATION [08/2015 - 08/2019] , or refer to INITIALIZATION [08/2019 - 08/2021] ).

  59. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 6

  60. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 6

  61. ADD POWER STEERING FLUID 
  62. BLEED POWER STEERING FLUID 

    Refer to PROCEDURE - Step 2

  63. INSPECT FOR OIL LEAK 

    Refer to PROCEDURE - Step 7

  64. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  65. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 18

  66. INSPECT ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 2

  67. INSPECT FOR POWER STEERING FLUID LEAK 
  68. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 17

  69. PERFORM RESET MEMORY 

    (Refer to INITIALIZATION [08/2015 - ] )

  70. INSPECT IGNITION TIMING 

    See step  1[08/2015 - 08/2019], or see step  1[08/2020 - ]

  71. INSPECT ENGINE IDLE SPEED 

    See step  2[08/2015 - 08/2019], or see step  2[08/2020 - ]

  72. INSPECT CO/HC 

    See step  4[08/2015 - 08/2019], or see step  4[08/2020 - ]

  73. INSTALL HOOD SUB-ASSEMBLY 
    1. Install the hood sub-assembly with the 8 bolts.

      for bolt A 

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

      for bolt B 

      Torque: 18 N*m (178 kgf*cm, 13 ft.*lbf) 

      GTY670298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the washer hose.
  74. ADJUST HOOD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  75. CHARGE REFRIGERANT 

    Refer to PROCEDURE - Step 2

  76. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  77. CHECK FOR REFRIGERANT GAS LEAK 

    Refer to PROCEDURE - Step 4

  78. INSTALL ENGINE ROOM SIDE COVER 
    1. Install the engine room side cover with the 4 clips.
  79. INSTALL ENGINE ROOM SIDE COVER LH 
    1. Install the engine room side cover LH with the 4 clips.
  80. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Attach the 2 V-bank cover hooks to the No. 1 V-bank cover bracket. Then align the 2 V-bank cover grommets with the 2 pins and press down on the V-bank cover sub-assembly to attach the pins.
      GTY666980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Pin
      *2 V-bank Cover Grommet
      *3 V-bank Cover Hook
      *4 No. 1 V-bank Cover Bracket
  81. INSTALL UPPER RADIATOR SUPPORT SEAL 
    1. Install the upper radiator support seal with the 14 clips.
  82. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL RH 
    1. Install the front No. 1 fender apron to frame seal RH with the 5 clips.
  83. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL LH 
    1. Install the front No. 1 fender apron to frame seal LH with the 5 clips.
  84. INSTALL FRONT FENDER APRON SEAL RH 
    1. Install the front fender apron seal RH with the 4 clips.
  85. INSTALL FRONT FENDER APRON SEAL LH 
    1. Install the front fender apron seal LH with the 7 clips.
  86. INSTALL REAR ENGINE UNDER COVER ASSEMBLY 
    1. Install the rear engine under cover assembly with the 4 bolts.

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

  87. INSTALL TRANSMISSION UNDER COVER 
    1. Install the transmission under cover with the 2 bolts.

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

  88. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY 
    1. Hook the No. 1 engine under cover sub-assembly to the vehicle body as shown in the illustration.
      GTY182185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 4 bolts.

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

  89. INSTALL LOWER FRONT BUMPER COVER 
    1. Install the lower front bumper cover with the 5 bolts and clip.

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

scientia non olet · About LEMON Manuals