Lexus IS250 · Service Manual ENGINE

REMOVAL

Removal / installation

1. REMOVE COOL AIR INTAKE DUCT SEAL

Remove the 11 clips and intake duct seal.

2. REMOVE ENGINE ROOM SIDE COVER LH

Remove the 5 clips and side cover.

3. REMOVE ENGINE ROOM SIDE COVER RH

Remove the 2 clips and side cover.

4. REMOVE V-BANK COVER SUB-ASSEMBLY

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. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM

Start up the engine.

Turn the A/C switch on.

Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible.

Stop the engine.

Using SST, let the refrigerant gas out.

SST

07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

6. DISCHARGE FUEL SYSTEM PRESSURE

7. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

9. REMOVE FRONT WHEEL

10. REMOVE ENGINE UNDER COVER

11. REMOVE NO. 2 ENGINE UNDER COVER

12. REMOVE ENGINE UNDER COVER REAR LH

Remove the bolt and engine under cover LH.

13. REMOVE ENGINE UNDER COVER REAR RH

HINT:
: Remove the RH side following the same procedures as with the LH side.

14. DRAIN ENGINE OIL

Remove the drain plug.

Install a new gasket and the drain plug.

Torque:

40 N*m{ 408 kgf*cm , 30 ft.*lbf }

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.

Remove the radiator cap and reservoir tank cap.

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.

16. REMOVE FRONT EXHAUST PIPE ASSEMBLY

17. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

18. REMOVE NO. 1 INLET AIR CLEANER

Remove the bolt, clip and inlet air cleaner.

19. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

Disconnect the MAF meter connector.

Disconnect the clamp from the air cleaner.

Disconnect the VSV hose.

Disconnect the 4 clamps.

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

20. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

Remove the 2 bolts, clamp and air cleaner case.

21. DISCONNECT UNION TO CHECK VALVE HOSE

Remove the clamp and disconnect the union to check valve hose.

22. DISCONNECT NO.2 FUEL VAPOR FEED HOSE

Remove the clamp and disconnect the No. 2 fuel vapor feed hose.

23. DISCONNECT INLET RADIATOR HOSE

Remove the clamp and disconnect the inlet radiator hose.

24. DISCONNECT OUTLET RADIATOR HOSE

Remove the clamp and disconnect the outlet radiator hose.

25. DISCONNECT RADIATOR RESERVOIR TANK HOSE

Remove the clamp and disconnect the radiator reservoir tank hose.

26. DISCONNECT INLET HEATER WATER HOSE

Disconnect the inlet heater water hose.

27. DISCONNECT OUTLET HEATER WATER HOSE

Disconnect the outlet heater water hose.

28. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE

Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor.

Remove the O-ring from the cooler refrigerant suction hose.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

29. REMOVE DISCHARGE HOSE SUB-ASSEMBLY

Remove the bolt and disconnect the discharge hose from the compressor.

Remove the O-ring from the discharge hose sub-assembly.

NOTICE:

Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

30. REMOVE ECM COVER

Remove the 3 bolts and ECM cover.
NOTICE:
1. Remove all water from on and around the ECM cover.
2. Perform the inspection indoors to avoid rain.
3. Be sure to prevent water intrusion to the ECM (connectors and screw parts).

31. DISCONNECT ENGINE WIRE

Disconnect the 6 ECM connectors.

Using a screwdriver, disconnect the connector holder.

Remove the engine room No. 1 relay block cover.

Remove the nut and disconnect the wire from the engine room No. 1 junction block.

Remove the nut and disconnect the battery positive (+) cable.

Disconnect the connector and remove the 4 clamps from body.

Remove the bolt, clamp and engine wire No. 3.

Remove the bolt and disconnect the ground cable.

32. DISCONNECT FUEL MAIN TUBE

33. DISCONNECT NO. 3 FUEL HOSE

Remove the clamp and disconnect the No. 3 fuel hose.

34. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR

Remove the 4 bolts and suspension member protector.

35. DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

Fix the steering wheel with the seat belt in order to prevent rotation.

HINT:

This operation is useful to prevent damage to the spiral cable.

Loosen bolt (A) and remove bolt (B), then slide the steering sliding yoke sub-assembly.
NOTICE:
1. Do not remove bolt (A).
2. Do not separate the steering sliding yoke sub-assembly from the power steering gear assembly.

Put matchmarks on the steering sliding yoke sub-assembly and the power steering gear assembly.

Separate the steering sliding yoke sub-assembly from the power steering gear assembly.

36. DISCONNECT HEIGHT CONTROL SENSOR LINK

Remove the nut and disconnect the height control sensor link.

37. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH

Loosen the bolt while holding the nut. Separate the lower part of the front shock absorber from the front suspension lower arm.

38. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH

HINT:
: Remove the RH side following the same procedures as for the LH side.

39. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH

Remove the 2 bolts from the front lower ball joint.

40. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH

HINT:
: Remove the RH side following the same procedures as for the LH side.

41. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET SUB-ASSEMBLY (for Automatic Transmission)

Remove the 2 bolts and exhaust pipe No. 1 support bracket sub-assembly.

42. DISCONNECT POWER STEERING LINK WIRE HARNESS

Remove the bolt (A) to disconnect the earth wire from the bracket.

Remove the 2 clamps to disconnect the wire harness from the bracket.

Disconnect the 2 connectors (C) and (D) from the power steering link assembly.

Release the lock of connector (E) and disconnect the connector from the power steering link assembly.

Remove the bolt (B) and the power steering earth wire from the power steering link assembly.

43. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

Set the shift lever to the neutral position.

Remove the nut, and separate the floor shift gear shifting rod sub-assembly.

44. REMOVE ENGINE AND TRANSMISSION ASSEMBLY

Set the engine lifter.

Remove the 4 bolts, then separate the engine rear mounting member.

Remove the 12 bolts shown in the illustration.

Operate the engine lifter, then slowly remove the engine from the vehicle.

NOTICE:

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

45. INSTALL ENGINE HANGERS

Install the No. 1 and No. 2 or No. 3 engine hangers with the 4 bolts as shown in the illustration.

Torque:

33 N*m{ 336 kgf*cm , 24 ft.*lbf }

Part No.:
No. 1 engine hanger
12281 - 31070

No. 2 engine hanger
12282 - 31050

Bolts
91671 - 10825

Attach an engine sling device and hang the engine with a chain block.

46. REMOVE STARTER ASSEMBLY

Disconnect the terminal 50 connector from the starter assembly.

Detach the terminal cap.

Remove the nut and disconnect the wire harness from terminal 30.

Remove the 2 bolts and starter.

47. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

48. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

49. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY

Remove the oil level gauge.

Remove the bolt, then remove the No. 2 oil dipstick guide.

Remove the O-ring from the No. 2 oil dipstick guide.

Remove the bolt and clamp, then remove the No. 1 oil dipstick guide.

Remove the O-ring from the No. 1 oil dipstick guide.

50. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

Disconnect the heated oxygen sensor connector.

Remove the 6 nuts, exhaust manifold and gasket.

51. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

Disconnect the heated oxygen sensor connector.

Remove the 6 nuts, exhaust manifold and gasket.

52. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

Using SST, hold the crankshaft.

SST

09213-70011 (09213-70020)
09330-00021

Remove the 8 bolts and the flywheel.

53. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

Using SST, hold the crankshaft.

SST

09213-70011 (09213-70020)
09330-00021

Remove the 8 bolts, front spacer, drive plate and rear spacer.

54. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

Remove the 2 bolts, then separate the front suspension crossmember sub-assembly from the engine.

55. FIX ENGINE ON ENGINE STAND

Fix the engine onto a engine stand with the bolts.

56. REMOVE V-RIBBED BELT

While releasing the belt tension by turning the belt tensioner counterclockwise, and remove the V-ribbed belt from the belt tensioner.

While turning the belt tensioner counterclockwise, align with its holes, and then insert the 5 mm bi-hexagon wrench into the holes to fix the belt tensioner.

57. REMOVE NO. 2 ENGINE COVER

Remove the 3 clips and clamp, then remove the No. 2 engine cover.

58. REMOVE NO. 1 ENGINE COVER

Remove the 3 clips, then remove the No. 1 engine cover.

59. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

Remove the bolt, plate and idler pulley.

60. REMOVE GENERATOR ASSEMBLY

Remove the terminal cap.

Remove the nut (A) and disconnect the wire harness from terminal B.

Remove the bolt (B) and clamp bracket.

Disconnect the generator connector, and detach the 2 clamps.

Remove the nut, and disconnect the generator bracket.

Remove the 2 bolts and generator.

Remove the 2 bolts and 2 generator brackets.

61. REMOVE COOLER COMPRESSOR ASSEMBLY

Disconnect the magnetic clutch connector.

Remove the 3 bolts and nut.

Remove the compressor and magnetic clutch.

62. REMOVE ENGINE MOUNTING BRACKET LH

Disconnect the 2 clamps.

Remove the 4 bolts and mounting bracket.

63. REMOVE ENGINE MOUNTING BRACKET RH

Remove the 4 bolts and mounting bracket.

64. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

Remove the 5 bolts, then remove the V-ribbed belt tensioner assembly.)

65. REMOVE WATER PUMP PULLEY

Using SST, hold the water pump pulley.

SST

09960-10010 (09962-01000, 09963-00700)

Remove the 4 bolts and water pump pulley.

66. REMOVE ENGINE WIRE

Remove the engine wire from the engine.

67. REMOVE INJECTOR DRIVER

Remove the bolt, 2 nuts and injector driver.

68. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

69. REMOVE NO. 2 SURGE TANK STAY

Remove the bolt and No. 2 surge tank stay.

70. REMOVE WATER HOSE JOINT

Remove the bolt, and disconnect 2 hoses and water hose joint.

71. REMOVE CRANKSHAFT PULLEY

Using SST, loosen the pulley bolt.

SST

09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)

Tighten the pulley bolt to 2 or 3 threads of the crankshaft.

Using SST, remove the pulley bolt and pulley.

SST

09213-70011 (09213-70020)
09330-00021

HINT:

Apply grease to the threads and tip of the SST (center bolt) prior to use.

Remove the pulley set key of the key groove.

72. REMOVE WATER INLET

Disconnect the 5 hoses.

Remove the 4 bolts, nut and water inlet.

Remove the water inlet housing gasket and water outlet pipe O-ring.

73. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

Remove the 15 bolts and 2 nuts.

Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

SST

09032-00100

NOTICE:

Be careful not to damage the contact surfaces of the oil pans.

74. REMOVE OIL PAN SUB-ASSEMBLY

Remove the 16 bolts and 2 nuts.

HINT:

Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder block and oil pan.

HINT:

Tape the screwdriver tip before use.

Remove the 2 O-rings.

75. REMOVE OIL STRAINER SUB-ASSEMBLY

Remove the 3 nuts, oil strainer and gasket.

Remove the 8 bolts and baffle plate.

76. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY

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

77. REMOVE NO. 1 FUEL PIPE

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

Disconnect the 2 fuel hoses.

Remove the 2 bolts and No. 1 fuel pipe.

78. DISCONNECT NO. 2 FUEL PIPE

Disconnect the fuel high pressure side fuel pump connector.

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.

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.

79. REMOVE FUEL PUMP ASSEMBLY

Disconnect the fuel hose.

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

80. REMOVE NO. 2 FUEL PIPE

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.

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

81. REMOVE IGNITION COIL ASSEMBLY

Remove the 6 bolts and 6 ignition coils.

82. REMOVE NO. 1 OIL PIPE

Remove the oil check valve bolt, oil pipe union and oil pipe.

Remove the oil control valve filter LH and gaskets.

83. REMOVE NO. 2 OIL PIPE

Remove the oil check valve bolt, oil pipe union and oil pipe.

Remove the oil control valve filter RH and gaskets.

84. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

Remove the 14 bolts, head cover and gasket.

Remove the 3 gaskets.

85. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

Remove the 12 bolts, head cover and gasket.

NOTICE:

The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the head cover.

Remove the 3 gaskets.

86. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

Remove the bolt and wiring harness clamp bracket.

Remove the 25 bolts and 2 nuts as shown in the illustration.

Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

HINT:

Tape the screwdriver tip before use.

Remove the gasket.

87. REMOVE TIMING CHAIN CASE OIL SEAL

Using a screwdriver, pry out the oil seal.

HINT:

Tape the screwdriver tip before use.