Lexus IS250 IS220d GSE20 ALE20 4GR-FSE ENGINE CONTROL SYSTEM

INSTALL ENGINE COOLANT TEMPERATURE SENSOR

INSTALL INTAKE MANIFOLD

INSTALL INTAKE AIR SURGE TANK ASSEMBLY

INSTALL THROTTLE BODY

INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

CONNECT NO. 2 VENTILATION HOSE

ADD ENGINE COOLANT

CHECK FOR ENGINE COOLANT LEAKS

CHECK FOR FUEL LEAKS

INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH

INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH

INSTALL FRONT WIPER ARM HEAD CAP

INSTALL ROOF DRIP SIDE FINISH MOULDING LH

INSTALL ROOF DRIP SIDE FINISH MOULDING RH

INSTALL FRONT FENDER PROTECTOR UPPER LH

INSTALL FRONT FENDER PROTECTOR UPPER RH

INSTALL V-BANK COVER SUB-ASSEMBLY

INSTALL ENGINE ROOM SIDE COVER LH

INSTALL ENGINE ROOM SIDE COVER RH

INSTALL COOL AIR INTAKE DUCT SEAL

ENGINE COOLANT TEMPERATURE SENSOR - INSTALLATION

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

Install a new gasket to the engine coolant temperature sensor.

Engine Coolant Temperature Sensor - Installation. 4GR-FSE ENGINE CONTROL SYSTEM. Lexus IS250 IS220d GSE20 ALE20

Install the engine coolant temperature sensor.

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

Connect the engine coolant temperature sensor connector.

2. INSTALL INTAKE MANIFOLD

Install a new gasket and the intake manifold with the 4 bolts and 4 nuts.

Torque:
21 N*m{ 214 kgf*cm, 15 ft.*lbf}

Connect the SCV position sensor connector.

Connect the DC motor connector for the SCV.

3. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

Install a new gasket to the intake air surge tank.

Using a 5 mm hexagon socket wrench, install the 6 bolts.

Torque:
Bolts except A:
18 N*m{ 184 kgf*cm, 13 ft.*lbf}

Install the bolt and 2 nuts to the intake air surge tank.

Torque:
Bolt A:
21 N*m{ 214 kgf*cm, 15 ft.*lbf}
Nut:
16 N*m{ 163 kgf*cm, 12 ft.*lbf}

Install the surge tank stay to the intake air surge tank.

Torque:
21 N*m{ 214 kgf*cm, 15 ft.*lbf}

Connect the water hose joint with the bolt.

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

Connect the ventilation hose to the intake air surge tank.

Connect the wire harness and hose to the intake air surge tank.

Connect the No. 1 vacuum switching valve assembly to the intake air surge tank.

Torque:
18 N*m{ 184 kgf*cm, 13 ft.*lbf}

Connect the vacuum hose to the intake air surge tank.

4. INSTALL THROTTLE BODY

Install a new gasket to the intake air surge tank.

HINT:

Align the protrusion of the gasket on the intake air surge tank.

Connect the 2 water by-pass hoses to the throttle body.

Install the throttle body with the 4 bolts.

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

Connect the throttle motor connector.

5. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

Install the air cleaner cap with air cleaner hose assembly with the 4 clamps and hose clamp.

HINT:

Be sure to install the air cleaner assembly so that the screw part of the hose clamp is as shown in the illustration.

Install the VSV hose to the air cleaner hose.

Connect the MAF meter connector and clamp to the air cleaner.

6. CONNECT NO. 2 VENTILATION HOSE

Connect the ventilation hose to the cylinder head cover with the clamp.

7. 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.

8. 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.

9. CHECK FOR FUEL LEAKS

Connect the intelligent tester to the DLC3.

Turn the engine switch on (IG).

NOTICE:

Do not start the engine.

Push the intelligent tester main switch ON.

Select the following menus: Powertrain / Engine / Active Test / Control the Fuel Pump /Speed.

Check the fuel pump operation.

Check for pressure in the fuel inlet tube from the fuel line. Check that sound of fuel flowing in the fuel tank can be heard.

If no sound can be heard, check the integration relay, fuel pump, ECM and wiring connector.

Check for fuel leaks.

Check that there are no fuel leaks anywhere on the system after performing maintenance.

If there is a fuel leak, repair or replace parts as necessary.

10. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

Engage the 11 claws.

Install the cowl top ventilator louver sub-assembly with the 2 clips.

11. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH

Operate the wiper, and stop the windshield wiper motor at the automatic stop position.

Clean the wiper arm serrations.

Clean the wiper pivot serrations with a wire brush (when reinstalling).

Install the front wiper arm and blade assembly LH with the nut at the position as shown in the illustration.

Torque:
22 N*m{ 224 kgf*cm, 16 ft.*lbf}

HINT:

Hold the arm hinge by hand to fasten the nut.

Area	Measurement
A	15 to 30 mm (0.59 to 1.18 in.)
B	Approx. 40 mm (1.57 in.)

12. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH

Operate the wiper, and stop the windshield wiper motor at the automatic stop position.

Clean the wiper arm serrations.

Clean the wiper pivot serrations with a wire brush (when reinstalling).

Install the front wiper arm and blade assembly RH with the nut at the position as shown in the illustration.

Torque:
22 N*m{ 224 kgf*cm, 16 ft.*lbf}

HINT:

Hold the arm hinge by hand to fasten the nut.

Area	Measurement
A	18.5 to 33.5 mm (0.73 to 1.32 in.)
B	Approx. 20 mm (0.79 in.)

Operate the front wipers while spraying washer fluid on the windshield glass. Make sure that the front wipers function properly and there is no interference with the vehicle body.

13. INSTALL FRONT WIPER ARM HEAD CAP