Lexus IS250 IS220d GSE20 ALE20 2AD-FHV ENGINE MECHANICAL

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. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

7. DISCONNECT NEGATIVE BATTERY TERMINAL

8. REMOVE FRONT WHEELS

9. REMOVE ENGINE UNDER COVER

10. REMOVE NO. 2 ENGINE UNDER COVER

11. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR

Remove the 4 bolts and suspension member protector.

12. REMOVE ENGINE UNDER COVER AIR GUIDE BRACKET

13. REMOVE ENGINE UNDER COVER REAR LH

Remove the 2 bolts and engine under cover air guide bracket.

14. REMOVE ENGINE UNDER COVER REAR RH

HINT:

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

15. DRAIN ENGINE OIL

Remove the oil pan drain plug and gasket, and drain the engine oil into a container.

16. DRAIN ENGINE COOLANT

CAUTION:

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.

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

Engine Assembly - Removal. 2AD-FHV ENGINE MECHANICAL. Lexus IS250 IS220d GSE20 ALE20

HINT:

Collect the coolant in a container and dispose of it according to local regulations.

17. REMOVE FRONT EXHAUST PIPE ASSEMBLY

HINT:

18. REMOVE PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING

HINT:

19. REMOVE NO. 1 INLET AIR CLEANER

Remove the bolt, clip and inlet air cleaner.

20. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

Disconnect the MAF meter connector.

Disconnect the 2 clamps from the air cleaner.

Disconnect the ventilation hose from the cylinder head.

Disconnect the 4 clamps.

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

21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

Remove the 3 bolts, clamp and air cleaner case.

22. REMOVE AIR DUCT (with Combustion Type Power Heater)

Remove the clip, clamp, and air duct.

23. REMOVE HEATER ASSEMBLY (with Combustion Type Power Heater)

Using pliers, grip the claws of the clip and slide the clip to disconnect the heater water inlet hose.

Using pliers, grip the claws of the clip and slide the clip to disconnect the heater water outlet hose.

Using pliers, grip the claws of the clip and slide the clip to disconnect the fuel hose.

Disconnect the connector.

Remove the 4 bolts and heater assembly.

24. DISCONNECT UNION TO CHECK VALVE HOSE

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

25. REMOVE WIRING HARNESS CLAMP BRACKET

Disconnect the wiring harness clamp.

Disconnect the 6 wire harness clamps (^*1).

Disconnect the EGR valve connector (^*2).

Disconnect the oil pressure switch assembly connector (^*3).

Remove the 2 bolts and wire harness clamp bracket.

26. REMOVE NO. 2 EGR PIPE

Remove the 2 nuts, 2 bolts and No. 2 EGR pipe.

27. REMOVE NO. 1 WATER OUTLET PIPE

Disconnect the manifold absolute pressure sensor connector and vacuum hose.

Remove the insulator.

Disconnect the 2 water hoses.

Remove the 3 bolts and No. 1 water outlet pipe.

28. REMOVE AIR PIPE SUB-ASSEMBLY

Disconnect the 2 diesel throttle body connectors.

Loosen the 3 hose bands.

Disconnect the intake air temperature sensor connector.

Remove the bolt and air pipe sub-assembly.

Disconnect the wire harness clamp.

29. DISCONNECT VACUUM TRANSMITTING HOSE

Remove the clamp and disconnect the vacuum transmitting hose.

30. DISCONNECT RESERVE TANK OUTLET HOSE

Remove the clamp and disconnect the reserve tank outlet hose.

31. DISCONNECT RADIATOR OUTLET HOSE

Disconnect the radiator outlet hose.

32. DISCONNECT HEATER WATER INLET HOSE

Disconnect the heater water inlet hose.

33. DISCONNECT HEATER WATER OUTLET HOSE

Disconnect the heater water outlet hose.

34. DISCONNECT NO. 1 AIR HOSE

Remove the clamp and disconnect the No. 1 air hose.

35. DISCONNECT 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.

36. DISCONNECT 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.

37. REMOVE DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

Disconnect the differential pressure sensor connector and remove the nut.

Disconnect the No. 1 vacuum transmitting hose and No. 2 vacuum transmitting hose.

Remove the differential pressure sensor.

38. DISCONNECT ENGINE WIRE

Remove the relay block cover.

Disconnect the engine wire from the engine room junction block.

Raise the 2 levers while pushing the locks on the 2 levers, and disconnect the 2 ECM connectors.

NOTICE:

After disconnecting the connector, make sure that dirt, water and other foreign matter does not contact the connecting part of the connector.

Remove the 2 nuts and disconnect the wire clamps from the engine room No. 1 junction block.

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

Disconnect 3 injector connectors and the 2 wire harness clamps.

39. DISCONNECT FUEL HOSE

Remove the clamp and disconnect the fuel hose.

40. DISCONNECT NO. 3 FUEL HOSE

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

41. 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:

Do not remove bolt (A).

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.

42. DISCONNECT HEIGHT CONTROL SENSOR LINK

Remove the nut and disconnect the height control sensor link.

43. DISCONNECT 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.

44. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

HINT:

Remove the RH side following the same procedure as for the LH side.

45. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH

Remove the 2 bolts from the front lower ball joint.

46. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH

HINT:

Remove the RH side following the same procedure as for the LH side.

47. DISCONNECT POWER STEERING LINK WIRE HARNESS (for LHD)

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.

48. REMOVE FLOOR SHIFT LEVER ASSEMBLY

HINT:

49. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION

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 does not get caught on wiring or hoses when removing it.

50. INSTALL ENGINE HANGERS

Install the 2 engine hangers with the 2 bolts.

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

Part name	Part No.
No. 1 engine hanger	12281-26040
No. 2 engine hanger	12282-26010
Bolt	91552-81025

NOTICE:

Use new bolts for the engine hangers.

51. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

52. REMOVE STARTER ASSEMBLY

Disconnect the 2 wire harness clamps from the wire harness clamp bracket.

Remove the bolt and wire harness clamp bracket.

Disconnect the terminal 50 connector from the starter assembly.

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

Remove the bolt, nut and starter assembly.

53. SEPARATE CLUTCH ACCUMULATOR ASSEMBLY

54. SEPARATE CLUTCH RELEASE CYLINDER ASSEMBLY

55. REMOVE MANUAL TRANSAXLE ASSEMBLY

HINT:

56. REMOVE CLUTCH DISC ASSEMBLY

HINT:

57. REMOVE FLYWHEEL SUB-ASSEMBLY

Hold the crankshaft with SST.

SST
09213-58013
09330-00021

Remove the 8 bolts and the flywheel.

58. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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

59. INSTALL ENGINE STAND

Fix the engine onto a engine stand with the bolts.

60. REMOVE ENGINE WIRE

Remove the engine wire from the engine assembly.

61. REMOVE V-RIBBED BELT

Release 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 its holes, and then insert a 5 mm (0.20 in.) bar into the holes to hold the belt tensioner.

62. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

Pinch the clip as illustrated, and then pull out the vacuum switching valve connector (^*1).

Disconnect the 2 vacuum hoses (^*2).

Using a hexagon socket wrench, remove the 2 bolts and No. 1 vacuum switching valve assembly (^*3).

63. REMOVE VACUUM REGULATING VALVE

Disconnect the 2 vacuum hoses.

Disconnect the vacuum regulating valve assembly connector.

Remove the 2 bolts, and then remove the vacuum regulating valve assembly.

64. REMOVE VACUUM SWITCHING VALVE BRACKET

Remove the 4 bolts and vacuum switching valve bracket.

65. REMOVE GENERATOR ASSEMBLY

Disconnect the generator connector.

Remove the bolt and disconnect the wire harness clamp bracket.

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

Disconnect the clamp from the clamp bracket.

Remove the 3 bolts (A) and generator assembly.

Remove the bolt (B) and clamp bracket from the generator assembly.

66. REMOVE IDLER PULLEY BRACKET

Remove the 2 bolts, 2 nuts and idler pulley bracket.

67. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

Using a screwdriver, remove the idler pulley cover plate.

Remove the bolt and idler pulley sub-assembly.

68. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

Remove the 3 bolts and tensioner assembly.

NOTICE:

Be careful not to deform the bolt head.

69. REMOVE ENGINE MOUNTING BRACKET LH

Remove the 4 bolts and mounting bracket.

70. REMOVE ENGINE MOUNTING BRACKET RH

Remove the 4 bolts and mounting bracket.

71. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY

Disconnect the magnetic clutch connector.

Remove the 3 bolts and nut.

Using a "Torx" socket wrench (E8), remove the stud bolt and the compressor assembly with pulley.

72. REMOVE NO. 1 COMPRESSOR STAY

Remove the No. 1 compressor stay from the engine block.

73. REMOVE TURBOCHARGER SUB-ASSEMBLY

HINT:

74. REMOVE EGR COOLER ASSEMBLY

HINT:

75. REMOVE EXHAUST MANIFOLD

Remove the 2 bolts and exhaust manifold heat insulator.

Remove the 8 nuts, 8 collars, exhaust manifold and gasket.

76. INSPECT EXHAUST MANIFOLD

Using a precision straightedge and feeler gauge, measure for any warpage on its cylinder head contact surface.

Maximum warpage:
0.2 mm (0.0079 in.)

If the warpage is greater than the maximum, replace the exhaust manifold.

77. REMOVE EGR VALVE ASSEMBLY

Remove the 2 bolts, EGR valve assembly and gasket.

78. REMOVE VACUUM PUMP ASSEMBLY

HINT:

79. REMOVE COMMON RAIL ASSEMBLY

Disconnect the fuel pressure sensor connector (^*1).

Disconnect the fuel hose.

Disconnect the pressure discharge valve connector (^*2).

Remove the 2 bolts and the common rail assembly.

80. REMOVE INJECTOR ASSEMBLY

HINT:

81. REMOVE GLOW PLUG ASSEMBLY

Remove the 5 grommets.

Remove the 5 nuts and the glow plug connector.

Remove the 4 glow plugs.

82. REMOVE OIL LEVEL GAUGE GUIDE

Remove the 3 bolts and oil level gauge.

Remove the O-ring from the oil level gauge.

83. REMOVE DIESEL THROTTLE BODY ASSEMBLY

Remove the 2 nuts and 2 bolts, and then remove the diesel throttle body and gasket.

84. REMOVE INTAKE MANIFOLD STAY

Remove the 2 bolts and intake manifold stay.

85. REMOVE INTAKE MANIFOLD

Remove the 7 bolts and 2 nuts, and then remove the intake manifold and the gasket.

86. INSPECT INTAKE MANIFOLD

Using a precision straightedge and feeler gauge, measure for any warpage on its cylinder head contact surface.

Maximum warpage:
0.1 mm (0.0039 in.)

If the warpage is greater than the maximum, replace the intake manifold.

87. REMOVE OIL COOLER ASSEMBLY

Disconnect the oil cooler hose.

Remove the 5 bolts, 3 O-rings and oil cooler assembly.

88. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

Remove the engine coolant temperature sensor.

89. REMOVE NO. 3 WATER BY-PASS PIPE

Remove the 2 bolts, O-ring and No. 3 water by-pass pipe.

90. REMOVE NO. 1 TURBO OIL PIPE

Remove the 2 union bolts, 2 gaskets and oil pipe.

91. REMOVE NO. 1 OIL COOLER BRACKET

Remove the 6 bolts and nut, and then remove the oil cooler bracket and the 3 O-rings.

92. REMOVE WATER INLET HOUSING

Remove the 2 bolts, O-ring and No. 2 water by-pass pipe.

Disconnect the hose.

Remove the 3 nuts, gasket and water inlet housing.

93. REMOVE ENGINE OIL LEVEL SENSOR

Remove the 4 bolts, then remove the oil level sensor and gasket.

94. REMOVE FUEL SUPPLY PUMP ASSEMBLY

HINT:

LEXUS IS250, IS220d / GSE20 ALE20

2AD-FHV ENGINE MECHANICAL

Lexus IS250 IS220d GSE20 ALE20

ENGINE ASSEMBLY