Lexus IS250 IS220d GSE20 ALE20 4GR-FSE CHARGING

INSTALL GENERATOR ASSEMBLY

INSTALL WIRE HARNESS

INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

INSTALL NO. 2 ENGINE COVER

INSTALL RADIATOR INLET HOSE

INSTALL V-RIBBED BELT

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

ADD ENGINE COOLANT

CHECK FOR ENGINE COOLANT LEAKS

INSTALL NO. 1 INLET AIR CLEANER

INSTALL V-BANK COVER SUB-ASSEMBLY

INSTALL ENGINE ROOM SIDE COVER LH

INSTALL COOL AIR INTAKE DUCT SEAL

PERFORM INITIALIZATION

GENERATOR - INSTALLATION

1. INSTALL GENERATOR ASSEMBLY

Install the 2 generator brackets with the 2 bolts.

Torque:
20 N*m{ 204 kgf*cm, 15 ft.*lbf}

Install the generator assembly with the 2 bolts.

Torque:
43 N*m{ 438 kgf*cm, 32 ft.*lbf}

Install the bracket with the nut.

Torque:
20 N*m{ 204 kgf*cm, 15 ft.*lbf}

Install the generator wire to terminal B with the nut (A).

Torque:
9.8 N*m{ 100 kgf*cm, 87 in.*lbf}

Install the terminal cap.

Install the clamp bracket with the bolt (B).

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Attach the 2 clamps, and connect the generator connector to the generator.

2. INSTALL WIRE HARNESS

Install the wire harness with the 3 nuts (A).

Torque:
10 N*m{ 102 kgf*cm, 7 ft.*lbf}

Connect the 2 connectors (B).

3. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

Install the pulley and cover plate with the bolt.

Torque:
43 N*m{ 438 kgf*cm, 32 ft.*lbf}

4. INSTALL NO. 2 ENGINE COVER

Install the No. 2 engine cover with the 3 clips.

Connect the clamp.

5. INSTALL RADIATOR INLET HOSE

Install the radiator inlet hose to the radiator assembly and secure it with the clips.

HINT:

Make sure that the claws on the clips are positioned as shown in the illustration.

Dimension "a" in the illustration (between the hose end and the clip end) should be less than 1.0 to 5.0 mm.

Connect the hose until it makes contact with the stopper. (Dimension "b" should be less than 2.5 mm)

6. INSTALL V-RIBBED BELT

Install the V-ribbed belt.

While turning the belt tensioner counterclockwise, remove the bar.

NOTICE:

Put the backside of the V-ribbed belt on the tensioner pulley and idler pulley.

Check that the V-ribbed belt is properly set to each pulley.

If it is difficult to install the V-ribbed belt, perform the following procedure.

Put the V-ribbed belt on every part except the tensioner pulley as shown in the illustration.

While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-ribbed belt on the tensioner pulley.

NOTICE:

Put the backside of the V-ribbed belt on the tensioner pulley and idler pulley.

Check that the V-ribbed belt is properly set to each pulley.

7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Torque:
5.4 N*m{ 55 kgf*cm, 48 in.*lbf}

8. ADD ENGINE COOLANT

Tighten all the plugs and fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

Torque:
13 N*m{ 130 kgf*cm, 9 ft.*lbf}for cylinder block drain cock plug

Add engine coolant.

Specified capacity:
9.1 liters (9.6 US qts, 8.0 lmp. qts)

HINT:

TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

Contact your TOYOTA dealer for further details.

Slowly pour coolant into the radiator reservoir until it reaches the FULL line.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level is low, add coolant.

Install the radiator cap and reservoir cap.

Bleed air from the cooling system.

NOTICE:

Before starting the engine to warm up the engine, turn the A/C switch OFF.

Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

HINT:

The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

NOTICE:

When pressing the radiator hoses:

Wear protective gloves.

Be careful as the radiator hoses are hot.

Keep your hands away from the radiator fans.

Maintain the engine speed at 2,000 to 2,500 rpm.

Press the inlet and outlet radiator hoses several times by hand to bleed air.

NOTICE:

When pressing the radiator hoses:

Wear protective gloves.

Be careful as the radiator hoses are hot.

Keep your hands away from the radiator fans.

Stop the engine, and wait until the engine coolant cools down to ambient temperature.

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.

Check the coolant level in the radiator reservoir.

If the coolant level is low, add SLLC to the radiator reservoir FULL line.

9. CHECK FOR ENGINE COOLANT LEAKS

NOTICE:

Before performing each inspection, turn the A/C switch OFF.

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.

Fill the radiator with coolant and attach a radiator cap tester.

Warm up the engine.

Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm², 17 psi), and check that the pressure does not drop.

If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

10. INSTALL NO. 1 INLET AIR CLEANER