Lexus - LS 600 - Workshop Manual - 2009 - 2009

Water Heater Feel the drive e1 Thermo Top Evo 5KW Parking Heater 00 0258 Installation documentation Lexus LS 460 / LS 600h Petrol from Model Year 2009 Left-hand drive vehicle Automatic air-conditioning Automatic transmission WARNING! Hazard warning: Observe the instructions of the vehicle manufacturer, allow jobs to be performed by electrical skilled persons only. Incorrect installation or repair of Webasto heating systems may cause a fire or result in the emission of carbon monoxide, which can be fatal. Serious or fatal injuries can be caused as a result. Specialist company training, technical documentation, specialised tools and equipment are required to install and repair Webasto heating and cooling systems. Only original Webasto parts must be used. For this, also see the catalog of air and water heater accessories from Webasto. NEVER attempt to install or repair Webasto heating or cooling systems if you have not successfully completed the company training and thereby acquired the required technical skills, or if you do not have access to the required technical documentation, tools and equipment needed to carry out correct installation and repairs. ALWAYS follow all Webasto installation and repair instructions and observe all warnings. The initial startup is to be executed with the Webasto Thermo Test Diagnosis. Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff. Ident. No.: 1316669A_EN Fee Euro 10.00 © Webasto AG Lexus LS 460 / LS 600h Table of Contents Validity Heater/Installation Kit Foreword General Instructions Special Tools Explanatory Notes on Document Preliminary Work Heater installation location Preparing electrical system LS 460 electrical system Electrical system LS600h Fan control Combination heater controls Digital timer 2 3 3 3 3 4 5 5 6 7 8 9 12 13 Telestart Preparing heater Preparing installation location Installing heater Fuel LS 460 coolant circuit LS 600h coolant circuit Final Work Template for Fuel Standpipe Operating Instructions for End Customer 13 15 17 18 20 25 32 40 41 42 Validity Manufacturer Lexus Model LS 460 Type F4 EG-BE No./ABE e6 * 2001 / 116 * 0108 * ... Engine type 1UR-FSE Engine model Petrol Output in kW 280 Displacement in cm³ 4608 Manufacturer Lexus Model LS 600h Type HF4 EG-BE No./ABE e6 * 2001 / 116 * 0109 * ... Engine type 2UR-FSE Engine model Petrol Output in kW 290 Displacement in cm³ 4969 Vehicle- and engine types, equipment variants and national specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible. 1316669A_EN 2 Lexus LS 460 / LS 600h Heater/Installation Kit Quantity 1 1 1 Description Basic delivery scope of Thermo Top Evo 5KW Installation kit Lexus LS 460 / LS 600h 2009 Petrol Heater control Order No.: See price list 1316670A See price list Foreword This installation documentation applies to the Lexus LS 460 / LS 600h Petrol vehicles - for validity, see page 2 - from model year 2009 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. Depending on the vehicle version and equipment, modifications may be necessary during installation with respect to this installation documentation. However, the stipulations in this "installation documentation", the "operating instructions" and the "installation documentation" for the Thermo Top Evo must always be observed. The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work. General Instructions Installation should be carried out according to the general, standard rules of technology. Unless specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses using cable ties. Sharp edges should be fitted with rub protection (split-open plastic hose). Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329). When installing an IPCU, the corresponding settings are to be checked or adjusted before the installation. Special Tools - Torque wrench for 2.0 - 10 Nm - Hose clamping pliers - Metric thread-setter kit 1316669A_EN 3 Lexus LS 460 / LS 600h Explanatory Notes on Document You will find an identification mark on the outside top right corner of the page in question to provide you with a quick overview of the individual working steps. Mechanical system Electrical system Coolant circuit Fuel Exhaust gas Combustion air Software Special features are highlighted using the following symbols: Specific risk of injury or fatal accidents. Specific risk of damage to components. Specific risk of fire or explosion. Reference to general installation instructions of Webasto components or to the manufacturer's vehicle-specific documents. Reference to a special technical feature. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. All dimensions are in mm! Install fuel connections without impacts. Tightening torque of 5x13 heater bolts = 8Nm! Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm! 1316669A_EN 4 Lexus LS 460 / LS 600h Preliminary Work WARNING! - Open the fuel tank cap, ventilate the tank. Close the fuel tank cap again. Disconnect battery from on-board power supply network. Drain the coolant from the cooling system. Copy the factory number from the original type label to the duplicate type label. Remove years that do not apply from the duplicate label. Attach the duplicate label (type label) in the appropriate place. Remove the air filter Remove the engine cover Remove coolant expansion tank Remove the bumper trim Remove the bumper. Remove air duct for brake on the right Remove underride protection Remove underbody trim on the right Remove the rear bench seat on the left Open the tank-fitting service lid on the right Remove the fuel-tank sending unit in accordance with manufacturer's instructions Remove footwell trim on the right Remove the glove compartment Remove page 42 "Operating Instructions for End Customer" and insert with vehicle operating instructions. Heater installation location 1 1 Heater Installation location 1 1316669A_EN 5 Lexus LS 460 / LS 600h Preparing electrical system 1 2 rt 0,5² 500 Cutting wires to length 3 sw 0,5² 4 br 0,5² 5 gn/ws 0,5² Connect wires to IPCU socket. IPCU view on contact side. The pre-programmed settings are to be checked during the function control on the vehicle, and adjusted if necessary. 1 15 A 86 IPCU 15 Duty cycle: Frequency: Voltage: Function: E 2 85 3 A E 86 60% 400Hz 9,0V Low-side Premounting IPCU 85 4 1 M5x12 bolt, washers [2x], nut 2 Fuse holder of passenger compartment 3 Angle bracket 1 3 Preparing fuse holder of passenger compartment 2 2 rt/sw rt gn/ws 0,5² 4² 0,75² F3 F4 Insert K1 relay and F4 10A in the fuse holder of the passenger compartment. Insert red (rt) wire in the K1/87a socket and black (sw) wire  in K1/30 socket 6 86 87 85 30 87a rt 4² Preparing relay K1 and fuse F4 K1 br 0,5² 1316669A_EN 7 sw 4² 6 Lexus LS 460 / LS 600h LS 460 electrical system Fuse holder of LS 460 engine compartment 1 M6x16 bolt, large diameter washer, flanged nut, existing hole 2 Angle bracket 3 Fuses F1-2 4 M5x16 bolt, washers [2x], retaining plate of fuse holder, nut 1 Wiring harness pass through of engine compartment, connection of earth wire LS 460 1 Protective rubber plug 2 Earth wire on earth support point 2 1 2 4 3 3 4 Wiring harness routing diagram Do not install the metering pump wiring harness until later together with fuel pipe along the original vehicle fuel lines on the underbody 1 1 2 5 6 Connecting LS 460 positive wire Wiring harness pass through of passenger compartment 1 Positive wire on positive support point 1 Protective rubber plug 2 Wiring harness of heater and heater control 1316669A_EN 7 Lexus LS 460 / LS 600h Electrical system LS600h Connecting earth wire LS 600 Connecting LS 600 positive wire 1 Original vehicle earth support point 1 Original vehicle positive support point 1 7 1 8 Wiring harness routing diagram Do not install the metering pump wiring harness until later together with fuel pipe along the original vehicle fuel lines on the underbody 1 1 2 3 4 9 10 Fuse holder of LS 600 engine compartment Wiring harness pass through LS 600 1 Fuses F1-2 2 M5x16 bolt, washers [2x], retaining plate of fuse holder, nut 3 Original vehicle flanged nut 4 Angle bracket Protect wiring harnesses with corrugated tubes. 1316669A_EN 1 Protective rubber plug 8 Lexus LS 460 / LS 600h Fan control Webasto Lexus 30 (B+) 15 (IG) HG 1 X2 F2 2 2 5 P-IG1-1 X1 HTR Wiring diagram F1 ge 0,5² rt gn/ws 4² 0,75² rt/sw rt gn/ws 0,5² 4² 0,75² rt/sw 0,5² br vi 0,5² 6 rt rt vi ws X10 F3 F4 86 87 L76 (A) 87a 30 br rt sw 0,5² br 3 AC-V K1 85 5 7 sw 2 0,5² ws rt 1 3 ws/sw 15 IPCU E Az3 3 2 1 A bl 85 4 br 86 1 gn/ws 0,75² 2 GE 3 A40 (A) M 5 31 (GND) Webasto components Vehicle components HG TT-Evo heater GE Fan unit 6-pin heater connector A40 (A) GE connector X1 2-pin heater connector AC-V A/C booster X2 X10 4-pin connector L76 (A) White (ws) 35-pin connecHeater control tor A/C-V K1 Fan relay P-IG1-1 Fuse 10A F1 Fuse 20A HTR 50 A fan fuse F2 Fuse 30A Az3 3-pin connector F3 Fuse 1A F4 Fuse 10A IPCU adjustment values: Duty cycle: 60% Frequency: 400Hz Voltage: 9,0V Function: Low-side 1316669A_EN Colours and symbols rt red ws white sw black br brown gn green vi violet Legend X Cutting point Wiring colours may vary. 9 Lexus LS 460 / LS 600h 1 1 Original vehicle bolt 2 Angle bracket 2 Installation of fuse holder in passenger compartment 11 Connect same colour wires of wiring harness of passenger compartment fuse holder 3 with wiring harness of heater 1 according to the wiring diagram. Connect additional green/white (gn/ws) wire  2 with green/white (gn/ws) wire of wiring harness of the passenger compartment fuse holder 3 . 1 Connecting wiring harnesses 3 2 12 Connection on white (ws) 35-pin connector L76 (A) 1, Pin 5 from A/C booster. Produce connections as shown in wiring diagram. 1 2 6 3 5 2 3 4 5 6 Violet (vi) wire of connector L76 (A) Black (sw) wire  of K1/30 Red (rt) wire  of K1/87a Red (rt) wire  to IPCU/15 Violet (vi) wire from fuse P-IG1-1 Connecting A/C booster 13 4 Connector L76 (A) on contact side. 1 8 2 3 4 5 6 Connector assignment L76 (A) 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 14 1316669A_EN 10 Lexus LS 460 / LS 600h 1 1 Angle bracket 2 M5x16 bolt, washers [2x], nut 3 IPCU socket 2 Premounting IPCU socket 15 3 1 Before installation, mount the green/white (gn/ws) wire  1 in the socket of IPCU/86. Mount IPCU. 2 Original vehicle bolt IPCU installation 16 2 1 Connection to 3-pin connector A3 1 of fan unit. Produce connections as shown in wiring diagram. 2 3 5 4 2 3 4 5 White (ws) wire to connector Az3 White (ws) wire from A/C heater control Pin 3 Red (rt) wire  to IPCU/E Black (sw) wire  to IPCU/A Connecting IPCU 17 1 Brown (br) wire  to IPCU/85, cable lug 2 Original vehicle earth support point 1 2 1316669A_EN Connecting earth wire 18 11 Lexus LS 460 / LS 600h Combination heater controls 1 Only for "silver" transmitter. See provided installation instructions for "black" transmitter. Telestart T91 with and without keys. Preparing connector Figure 11 (Y-adapter of connector) 2 Detach violet (vi) wire 2 from 6-pin connector 1 Pin5 and insert it in Pin2 19 4 1 3 2 1 Digital timer and Telestart T91. 2 Figure 20a (Y-adapter coupling, wire-side view) 5 3 Detach, insulate and tie back violet (vi) wire 4 from 4-pin coupling 1 Pin1. Detach black (sw) wire 5 from 4-pin coupling 1 Pin2 and insert it in Pin1. Preparing connector Figure 20b (Y-adapter of connector) Detach black (sw) wire 3 from 6-pin connector 2 Pin3 and insert it in Pin2. 20a 20b 4 Telestart T100 HTM with and without keys. 1 Figure 21 (Y-adapter of connector) Detach violet (vi) wire 2 from 6-pin connector 1 Pin5. Cut yellow (ge) wire 3 approx. 50mm before connector 1. Connect violet (vi) wire 2 and yellow (ge) wire 3 to connector. 3 21 2 4 1 3 2 Preparing connector 1 Digital timer and Telestart T100 HTM! 2 Figure 22a (Y-adapter coupling, wire-side view) 3 6 Detach, insulate and tie back violet (vi) wire 5 from 4-pin coupling 1 Pin1. Detach black (sw) wire 6 from 4-pin coupling 1 Pin2 and insert it in Pin1. Preparing connector Figure 22b (Y-adapter of connector) 22a 1316669A_EN 5 4 22b Detach black (sw) wire 4 from 6-pin connector 2 Pin3. Cut yellow (ge) wire 3 approx. 50mm before connector 2. Connect black (sw) wire 4 and yellow (ge) wire 3 to connector. 12 Lexus LS 460 / LS 600h Kabelbaum Heizgerät 9004584A Heater controls diagram Vorwahluhr Telestart Taster Digital timer 1 1 Digital timer Installing digital timer 23 Telestart 1 Detach player 2 and fasten receiver 1 with adhesive tape. Installing receiver 24 2 Paste antenna 1 in the black area of the windscreen. 1 Installing antenna 25 1316669A_EN 13 Lexus LS 460 / LS 600h Temperature sensor T100 HTM Fasten temperature sensor 1 with adhesive tape. 1 Installing temperature sensor 26 1316669A_EN 14 Lexus LS 460 / LS 600h 1 Preparing heater 2 1 Exhaust pipe a = 130 2 Exhaust end section b = 25 Discard section X a Preparing exhaust pipe b X 1 Combustion air pipe a = 300 1 Discard section X Cutting combustion air pipe to length a X LS 460 A B C D F E K J I Hose I and H will be cut to length later. Discard section X G X X X H 1 = = = = = = = = = 110 730 170 60 120 860 90 55 270 Cutting hoses to length Push braided protection hose onto hose B, F and K and cut to length. Cut heat shrink plastic tubing to length. 1 B 1 A B C D E F G J K 1 1 Heat shrink plastic tubing, 50 mm long [6x] Preparing hoses F K 1 1 1316669A_EN 15 Lexus LS 460 / LS 600h LS 600h A B C E D Hose G and H will be cut to length later. Discard section X F A B C D E F I I H X X X G 1 500 170 60 120 750 90 240 Cutting hoses to length Push braided protection hose onto hose A and E and cut to length. Cut heat shrink plastic tubing to length. 1 A 1 = = = = = = = 1 1 Heat shrink plastic tubing, 50 mm long [6x] Preparing hoses E I 1 1 All vehicles 1 2 1 1 1 Coolant connection piece, sealing ring [2x each] 2 5x15 self-tapping bolt, retaining plate of coolant connection piece Installing coolant connection piece 27 Hose D = heater inlet LS 460h Hose E = heater outlet LS 460h Hose C = heater inlet LS 600h Hose D = heater outlet LS 600h 2 C/D 2 1 18x18mm, 90° connecting pipe [2x] 2 25mm dia. spring clip [4x] Premounting hoses 2 D/E 1316669A_EN 2 28 16 Lexus LS 460 / LS 600h 1 90° moulded hose, 10mm dia. clamp [2x] 2 Fuel line Premounting fuel line 2 29 1 1 3mm dia. drain hole 4 in exhaust silencer 3. Mount exhaust end section 5 and lock with 4 blows of a staking punch. 2 1 1 Hose clamp [2x] 2 Exhaust pipe 3 Premounting exhaust system 4 30 5 Bend tab 2 of bracket 1 by 90°. Apply corrosion protection at bending point. 1 Preparing bracket 31 2 1 Preparing installation location 2 Position bracket 2 and align it parallel to bumper edge 3. 15 1 Bumper 4 Copy hole pattern, 7mm dia. hole [3x] Copying hole pattern 4 80 3 1316669A_EN 32 17 Lexus LS 460 / LS 600h 1 1 M6x20 bolt, pin lock [3x each] 1 Premounting bolts 1 33 1 2 1 2 3 4 5 3 Combustion air pipe Flanged nut [3x] Bracket 48mm p-clamp Silencer Installing bracket 4 2 5 1 2 34 Installing heater 1 1 5x15 Self-tapping bolt [3x] 2 M6x25 bolt, spring lockwasher, 15mm spacer nut Installing heater 1 2 35 1 25mm dia. spring clip 2 Combustion air pipe Installing combustion air pipe 1 2 1316669A_EN 36 18 Lexus LS 460 / LS 600h Wrap bumper and air cleaner housing 1 with insulation material 2. Installing bumper 1 37 2 Position air filter 1 laterally in bumper. Installing air filter 38 1 1 Wiring harness of circulating pump 2 Wiring harness of heater [2x] 1 Mounting wiring harnesses 2 1316669A_EN 2 39 19 Lexus LS 460 / LS 600h Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Catch any fuel running off with an appropriate container. Install fuel line and metering-pump wiring harness so that they are protected against stone impact. Unless specified otherwise, always fasten using cable ties. Mount the fuel line and wiring harness with rub protection on sharp edges. WARNING! The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness routing diagram. 1 2 3 Detach external connector housing 1 by opening lock 2 of the connector of metering pump 6. Remove coding 4. Remove blue (bl) wire 3 and brown (br) wire 7 from the connector of the metering pump 6 by opening the lock 5 [2x]. Will be inserted again later. Pin assignment is not relevant. 4 Removing wires 5 5 7 6 40 Pull fuel line 3 and wiring harness of metering pump 1 into 2100mm long corrugated tube 2 and route to the engine compartment (see wiring harness routing to engine compartment). Installing lines 3 1 2 41 Route wiring harness of metering pump and fuel line into 10mm dia., 2100mm long corrugated tube 1 to the firewall (see fuel). 1 Installing lines 42 1316669A_EN 20 Lexus LS 460 / LS 600h Cut open 17mm dia., 200mm long corrugated tube 2 lengthwise and slide onto wiring harnesses of heater, heater control and earth wire. Route wiring harness of heater control in 10mm dia., 1130mm long corrugated tube 1 to the firewall. 1 Installing lines 43 2 1 2 3 4 Route 10mm dia., 2100mm long corrugated tube 1 and 10mm dia., 1130mm long corrugated tube 4 through rubber-coated pipe clamp 2. Route corrugated tube 1 further on the firewall to the underbody. 3 M6x20 bolt, spring lock washer, 29mm dia. rubber-coated p-clamp, existing threaded hole Installing lines 44 1 Fuel line and wiring harness for metering pump in corrugated tube Installing lines 45 1 1 Fuel line and wiring harness for metering pump in corrugated tube 1 Installing lines 46 1316669A_EN 21 Lexus LS 460 / LS 600h 1 2 1 Perforated bracket section 2 2 Cutting line 3 Perforated bracket section 1 3 Cutting perforated bracket to size 60 1 Perforated bracket section 1 1 Angling down perforated bracket section 1 25 55° 1 Perforated bracket section 2 1 Angling down perforated bracket section 2 28 50° Discard rubber plug at position 1. 1 M6 rivet nut, existing hole Installing rivet nut 1 1316669A_EN 47 22 Lexus LS 460 / LS 600h 1 M6x20 bolt, spring lockwasher 2 Perforated bracket section 2 3 M6x25 detent-edged bolt, pin lock 1 Installing perforated bracket section 2 2 48 3 1 1 2 3 4 2 Metering pump Receptacle for metering pump Perforated bracket section 1 M6 flanged nut Installing metering pump 3 4 1 49 Check the position of the components; adjust if necessary. Check that they have freedom of movement. 2 1 Fuel line of heater 2 Hose section, 10 mm dia. clamp [2x] 3 Wiring harness of metering pump, connector mounted 3 Connecting metering pump 50 Remove and dismantle fuel-tank sending unit 1 according to manufacturer's instructions. 2 Large diameter washer, dia. da = 14,8 mm 3 Copy hole pattern, 6 mm dia. hole 1 Removing fuel 3 2 1316669A_EN 51 23 Lexus LS 460 / LS 600h Shape fuel standpipe 1 according to template, cut to length and install. 1 Installing fuel standpipe 52 1 Install fuel-tank sending unit according to manufacturer's instructions. 2 1 2100mm long corrugated tube 2 Fuel line 3 Hose section, 10 mm dia. clamp [2x] 3 Connecting fuel line 53 Check the position of the components; adjust if necessary. Check that they have freedom of movement. 1 1 Hose section, 10 mm dia. clamp [2x] 2 Fuel line of fuel standpipe Connecting metering pump 2 54 1316669A_EN 24 Lexus LS 460 / LS 600h LS 460 coolant circuit WARNING! Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. When installing the hoses, the heater must be filled with coolant. The connection should be "inline" based on the following diagram: Coolant routing diagram A 1 1 I H 3 B J 2 2 G 4 C K F D 2 2 E All spring clips = 25mm dia. 1 = Original vehicle spring clip 2 = Black (sw) rubber isolator All connecting pipes and 4 = Check valve . 1316669A_EN . 3 = 90° T-piece = 18x18mm dia. . 25 Lexus LS 460 / LS 600h 1 Discard clip 2 Cutting point 3 Discard section H 70 Cutting coolant hose H to length 3 2 55 1 1 Discard section 2 Cutting point I Cutting coolant hose I to length 10 2 1 1 56 1 Slide spring clip onto hose [2x] 2 T-piece A Premounting T-piece 1 J 2 57 1 H Pay attention to the direction of flow of check valve 3. Slide 100mm heat shrink plastic tubing 1 onto hose H and shrink. 2 Position black (sw) rubber isolator 3 G K Premounting check valve 2 58 1316669A_EN 26 Lexus LS 460 / LS 600h 1 70mm long narrow edge protection 2 50mm long broad edge protection Installing edge protection 2 1 59 1 Discard hose section on heat exchanger outlet 2 Discard hose section on engine outlet 1 Cutting point 2 60 Bend pipe of heat exchanger inlet 1 if necessary towards the engine. 1 Connecting hose H H 61 Install hose I with shortened side on connection piece of engine outlet 1. 1 Connecting hose I I 62 1316669A_EN 27 Lexus LS 460 / LS 600h 1 Align T-piece and ensure sufficient distance from pulley at position 2. I 1 Pipe of heat exchanger outlet A Connecting T-piece J 63 2 1 Align black (sw) rubber isolator I Connecting hose K K 64 1 1 Install hose B on T-piece. Fasten black (sw) rubber isolator 3 with cable tie 1 [2x]. 2 2 Hose H fastened with cable tie H Connecting hose B D 65 B 3 H Ensure sufficient distance between pulley 2 and hose B at position 1. 1 Checking the distance from pulley B 2 1316669A_EN 66 28 Lexus LS 460 / LS 600h 1 M6 rivet nut in existing hole 1 Installing rivet nut 67 1 Dismantle original vehicle bolt Preparing installation of circulating pump 68 1 1 Shorten large diameter washer Preparing installation of circulating pump 1 69 1 Perforated bracket 1 20 Angling down perforated bracket 2x 90° 50 70 1316669A_EN 29 Lexus LS 460 / LS 600h 1 2 3 4 1 48mm dia. rubber-coated p-clamp Mount M6x20 bolt, flanged nut loosely Perforated bracket Circulating pump 2 Preparing circulating pump 3 71 4 Aligning circulating pump. Tighten M6x20 bolt, flanged nut. 1 1 Mount wiring harness of circulating pump 2 Original vehicle bolt Installing circulating pump 72 2 B Connecting hose B 73 1 Hose D with 90° connecting pipe 1 E Connecting hose C C 74 1316669A_EN 30 Lexus LS 460 / LS 600h 1 Cable tie F Connecting hose F C 1 75 Shape rubber-coated 48mm dia. p-clamp 1 as shown. Shaping rubbercoated pclamp 76 1 1 2 1 2 3 4 5 B M6x20 bolt, spring lockwasher M6x20 bolt, flanged nut M6 Cable tie Rubber-coated pipe clamp Angle bracket Routing in engine compartment 3 5 4 F 77 Ensure sufficient distance to neighbouring components. B 1 Spacer bracket G F 1316669A_EN 1 Connecting hose F 78 31 Lexus LS 460 / LS 600h LS 600h coolant circuit WARNING! Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. When installing the hoses, the heater must be filled with coolant. The connection should be "inline" based on the following diagram: Hose routing diagram H 1 G 3 I 2 B F 4 2 E C 2 D A 5 All spring clips = 25mm dia. 1 = Original vehicle spring clip 2 = Black (sw) rubber isolator All connecting pipes and 4 = Check valve . 5 = 90° T-piece ! 1316669A_EN . 3 = Original vehicle water pump. = 18x18mm dia. 32 Lexus LS 460 / LS 600h 1 2 1 Original vehicle spring clips will be required again [2x] 2 Dismantle pipe group 3 Remove and discard hose section on heat exchanger outlet Cutting point 3 1 79 Align pipe end1 by 15mm in the direction of the arrow, see following Figure. Prevent breaking of pipe. Aligning pipe group 80 1 1 Pipe group installed Installing pipe group 1 81 1 Discard clip 2 Cutting point 3 Discard section G 80 Cutting coolant hose G to length 3 1316669A_EN 2 1 82 33 Lexus LS 460 / LS 600h 1 Discard section 2 Cutting point H Cutting coolant hose H to length 10 2 1 1 83 2 G 5 3 F I 4 2 Pay attention to the direction of flow of check valve 5. Slide 100mm heat shrink plastic tubing 1 onto hose G and shrink. Cut 300mm braided protection hose 3 to length and slide onto hose I. 2 Slide on 50mm heat shrink plastic tubing [2x] and shrink 4 Position black (sw) rubber isolator Premounting check valve 84 1 Position black (sw) rubber isolator Premounting hose E E 85 1 1 Pipe of heat exchanger inlet 1 Connecting hose G G 86 1316669A_EN 34 Lexus LS 460 / LS 600h Install hose H with shortened side on connection piece of engine outlet 1. H Connecting hose H 1 I 87 1 Fasten hose I with cable tie 1. I 2 Fasten check valve with cable tie [2x] 3 Remove original vehicle hose 4 Align black (sw) rubber isolator Fastening hoses 2 3 4 88 2 Ensure sufficient distance between pulley 1 and hose G at position 2. 1 Checking the distance from pulley 2 G 89 1 Discard section 70 20 1 1316669A_EN Cutting original vehicle hose to length 90 35 Lexus LS 460 / LS 600h 1 Original vehicle hose 2 T-piece 1 Premounting T-piece A 91 2 1 Original vehicle hose [2x] 2 T-piece 1 Installing original vehicle hose 2 1 92 Shape rubber-coated 48mm dia. p-clamp 1 as shown. Shaping rubbercoated pclamp 93 1 1 Discard original vehicle bolt at position 3. Install 5mm shim between angle bracket 1 and body. 2 2 M6x20 bolt, 48mm dia. rubber-coated pclamp, flanged nut 3 M6x20 bolt, spring lockwasher, 5mm shim, original vehicle threaded hole 3 1316669A_EN Installing rubbercoated pclamp 94 36 Lexus LS 460 / LS 600h 1 70mm long narrow edge protection 2 50mm long broad edge protection Installing edge protection 2 1 95 Route hose A and E through rubber-coated p-clamp 1. 1 Routing hose A and E E A 96 1 Dismantle original vehicle bolt Preparing installation of circulating pump 1 97 1 Shorten large diameter washer 1 Preparing installation of circulating pump 98 1316669A_EN 37 Lexus LS 460 / LS 600h 1 Perforated bracket 1 20 Angling down perforated bracket 2x 90° 50 99 1 2 3 4 1 48mm dia. rubber-coated p-clamp Mount M6x20 bolt, flanged nut loosely Perforated bracket Circulating pump 2 Preparing circulating pump 3 100 4 Aligning circulating pump. Tighten M6x20 bolt, flanged nut. 1 1 Mount wiring harness of circulating pump 2 Original vehicle bolt Installing circulating pump 101 2 A Connecting hose A 102 1316669A_EN 38 Lexus LS 460 / LS 600h 1 Hose C with 90° connecting pipe 1 D Connecting hose B B 103 1 Cable tie E Connecting hose E B 1 104 1316669A_EN 39 Lexus LS 460 / LS 600h Final Work WARNING! Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Secure all loose cables using cable ties. Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl 100K, Order No. 111329). - Connect the battery Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications. Set the digital timer. Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Apply the sticker "Switch off parking heater before refilling" in the area of the filler neck. - For initial startup and function test, see installation instructions Cut out wheel-well inner panel 1 at the markings. Discard section 2. 1 Cutting out wheel-well inner panel 105 2 1 Position exhaust end section at the centre of the recess 1 Exhaust end section 106 Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78 (14 Cent aus dem deutschen Festnetz) Hotfax: 0395 5592 353 Hotmail: [email protected] http://www.webasto.com 1316669A_EN Printed in Germany 08/2011 Printing: Steffen 40 Lexus LS 460 / LS 600h Template for Fuel Standpipe 100mm Scale 1:1 Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimise margins” and 100% of the normal size. 100mm 0 1316669A_EN 41 Lexus LS 460 / LS 600h Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min. For vehicles with passenger compartment monitoring this must be deactivated in addition to defining the vehicle settings for the heating operation. Instructions on deactivation can be taken from the operating instructions of the vehicle. Before parking the vehicle, make the following settings: 1 Set temperature to "HI" [2x] 2 Air outlet to windscreen on both sides Automatic air-conditioning 1 1 2 1316669A_EN 107 42