Lexus IS250 · Service Manual ENGINE

REMOVAL

Removal / installation


1. REMOVE COOL AIR INTAKE DUCT SEAL

  1. A127530
    Remove the 11 clips and intake duct seal.


2. REMOVE ENGINE ROOM SIDE COVER LH

  1. A123702E01
    Remove the 5 clips and side cover.


3. REMOVE ENGINE ROOM SIDE COVER RH

  1. A123703E01
    Remove the 2 clips and side cover.


4. REMOVE V-BANK COVER SUB-ASSEMBLY

  1. A127528
    Raise the V-bank cover to disengage the clip on the rear of the cover. Raise the cover again to disengage the 2 clips on the front of the cover and remove the cover.

    NOTICE:
    Attempting to disengage both front and rear clips at the same time may cause the cover to break.


5. REMOVE FRONT UPPER FENDER PROTECTOR LH

  1. E119591
    Using a clip remover, separate the clip on the rubber portion of the cowl top ventilator louver sub-assembly from the front upper fender protector LH.

  1. Disengage the 3 clips and the claw to remove the front fender protector upper LH.


6. REMOVE FRONT UPPER FENDER PROTECTOR RH

HINT:
Removal procedure of the RH side is the same as that of the LH side.


7. REMOVE ROOF DRIP SIDE FINISH MOULDING LH

  1. Put protective tape around the roof drip side finish moulding.

  1. Using a moulding remover, disengage the 6 clips and remove the roof drip side finish moulding.

    NOTICE:
    1. Do not remove the clips.
    2. If the clips are damaged or fall off, replace them with new clips.


    B125564E01


8. REMOVE ROOF DRIP SIDE FINISH MOULDING RH

HINT:
Removal procedure of the RH side is the same as that of the LH side.


9. REMOVE FRONT WIPER ARM HEAD CAP

  1. E119593E01
    Using a screwdriver, remove the front wiper arm head cap.

    HINT:
    1. Use the same procedures for the RH side and the LH side.
    2. Tape the screwdriver tip before use.


10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

  1. E119604
    Remove the nut and the front wiper arm and blade assembly LH.


11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

  1. E119605
    Remove the nut and the front wiper arm and blade assembly RH.


12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

  1. E119595
    Remove the 2 clips.

  1. E119597
    Disengage the 11 claws, and pull out the cowl top ventilator louver sub-assembly.


13. DISCHARGE FUEL SYSTEM PRESSURE

HINT:
Click here.


14. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

15. DRAIN ENGINE COOLANT

NOTICE:
Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

  1. Remove the radiator cap and reservoir tank cap.

  1. Loosen the radiator drain cock plug and 2 cylinder block drain cock plugs. Then drain the coolant.

    HINT:
    Collect the coolant in a container and dispose of it according to the regulations in your area.


    A120242E01


16. DISCONNECT NO. 2 VENTILATION HOSE

  1. A103629
    Disconnect the ventilation hose from the cylinder head.


17. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

  1. A124986
    Disconnect the MAF meter connector.

  1. Disconnect the clamp from the air cleaner.

  1. A103631
    Disconnect the VSV hose.

  1. A126225
    Disconnect the 4 clamps.

  1. Remove the hose clamp and air cleaner cap with air cleaner hose.


18. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

  1. Disconnect the throttle motor connector.

  1. A103952
    Remove the 4 bolts and disconnect the throttle body from the intake air surge tank.

  1. A103634
    Disconnect the 2 water by-pass hoses from the throttle body.

  1. Remove the throttle body and gasket.


19. REMOVE INTAKE AIR SURGE TANK

  1. A125211
    Disconnect the vacuum hose from the intake air surge tank.

  1. Remove the bolt and disconnect the No. 1 vacuum switching valve assembly from the intake air surge tank.

  1. A123886
    Disconnect the wire harness and hose from the surge tank.

  1. A126653
    Disconnect the ventilation hose from the intake air surge tank.

  1. A122441
    Remove the bolt and water hose joint from the intake air surge tank.

  1. A126654
    Remove the bolt and disconnect the surge tank stay.

  1. A103645
    Using a 5 mm hexagon socket wrench, remove the 7 bolts, 2 nuts and gasket.


20. REMOVE INTAKE MANIFOLD

  1. Disconnect the connector for the SCV.

  1. Disconnect the SCV position sensor connector.

  1. A103762E01
    Remove the 4 bolts, 4 nuts, intake manifold and gasket.


21. DISCONNECT WATER HOSE JOINT

  1. A120911
    Remove the bolt and water hose joint.


22. REMOVE FUEL PRESSURE PULSATION DAMPER

  1. A120840E01
    Using SST, remove the fuel pressure pulsation damper from the fuel pump.


23. REMOVE NO. 1 FUEL PIPE

  1. A114836
    Disconnect the No. 3 fuel hose from the No. 1 fuel pipe.

  1. A121862
    Disconnect the 2 fuel hoses.

  1. Remove the 2 bolts and No. 1 fuel pipe.


24. DISCONNECT NO. 2 FUEL PIPE

  1. Disconnect the fuel high pressure side fuel pump connector.

  1. A104005
    Fix the union bolt on the fuel pump side in place with a 21 mm wrench. Using a 19 mm union nut wrench, loosen the union and remove the fuel pipe.

    NOTICE:
    1. There must be absolutely no free play in the union on the fuel pump side.
    2. If the union on the fuel pump side has free play, replace the fuel pump.

  1. A121865
    Remove the 2 bolts on the delivery pipe side.

    NOTICE:
    1. Do not remove the fuel pipe from the delivery pipe. Only remove the 2 bolts.
    2. If the No. 2 fuel pipe is accidentally removed, replace its O-ring, No. 1 backup ring and No. 2 backup ring.


25. REMOVE FUEL PUMP ASSEMBLY

  1. A104007
    Disconnect the fuel hose.

  1. Remove the 2 nuts, fuel pump and fuel pump insulator.


26. REMOVE NO. 2 FUEL PIPE

  1. A121853
    Remove the fuel pipe from the fuel delivery pipe.

    NOTICE:
    Pull and remove the fuel pipe in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.

  1. Remove the O-ring, backup rings and E-ring from the No. 2 fuel pipe.


27. REMOVE NO. 3 FUEL PIPE

  1. A103982E01
    Remove the 4 bolts and fuel pipe from the fuel delivery pipe.

    NOTICE:
    Pull and remove the fuel pipe in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.

  1. Remove the O-ring, backup rings and E-ring from the No. 3 fuel pipe.


28. REMOVE NO. 2 FUEL DELIVERY PIPE

  1. A103983E02
    Disconnect the 3 wire harness clamps.

  1. Remove the 2 bolts and 2 nuts.

  1. A103984E01
    With the connectors still connected, disconnect the delivery pipe.

    NOTICE:
    1. Make sure that the fuel delivery pipe is disconnected from the delivery pipe (LH side).
    2. Be extremely careful not to touch or strike the tips of the injectors.
    3. Pull and remove the fuel pipe in a straight line without tilting it.

  1. Disconnect the 3 connectors from the 3 injectors.

  1. Remove the 3 injector vibration insulators from the cylinder head.


29. REMOVE NO. 1 FUEL DELIVERY PIPE

  1. A103985E02
    Disconnect the 2 wire harness clamps.

  1. Remove the 2 bolts and 2 nuts.

  1. A103986E01
    With the connectors still connected, disconnect the No. 1 fuel delivery pipe.

    NOTICE:
    1. Be extremely careful not to touch or strike the tips of the injectors.
    2. Pull and remove the fuel pipe in a straight line without tilting it.

  1. Disconnect the 3 connectors from the 3 injectors.

  1. Remove the 3 injector vibration insulators from the cylinder head.


30. REMOVE FUEL INJECTOR

  1. A127912
    Secure the delivery pipe in a vise between aluminum plates and pull out the injector in a straight line.

    NOTICE:
    1. Pull and remove the injector in a straight line to avoid damage to the seal surface of the delivery pipe's O-ring.
    2. For reinstallation, attach a tag or label to the injector shaft.

  1. Remove the nozzle holder clamps from the injectors.

  1. Remove the O-ring, backup rings and E-ring from the fuel injector.


31. REMOVE FUEL INJECTOR SEAL

  1. A103987
    Using the tips of a pair of needle nose pliers, pinch and pull one of the 2 injector seals at several points to stretch it. Repeat this for the other injector seal.

    NOTICE:
    1. Excessively pinching the injector seal may damage the groove of the injector.
    2. If an injector is dropped or the tips of the injectors are struck, replace it with a new one.

  1. Remove the 2 injector seals from the injector.

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