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

HINT:

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 AIR GUIDE BRACKET

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

13. REMOVE ENGINE UNDER COVER REAR LH

Remove the bolt and engine under cover LH.

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 drain plug.

Install a new gasket and the drain plug.

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

16. 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.

Engine Assembly - Removal. 4GR-FSE ENGINE MECHANICAL. Lexus IS250 IS220d GSE20 ALE20

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 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.

21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

Remove the 2 bolts, clamp and air cleaner case.

22. DISCONNECT UNION TO CHECK VALVE HOSE

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

23. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE

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

24. DISCONNECT INLET RADIATOR HOSE

Remove the clamp and disconnect the inlet radiator hose.

25. DISCONNECT OUTLET RADIATOR HOSE

Remove the clamp and disconnect the outlet radiator hose.

26. DISCONNECT RADIATOR RESERVOIR TANK HOSE

Remove the clamp and disconnect the radiator reservoir tank hose.

27. DISCONNECT INLET HEATER WATER HOSE

Disconnect the inlet heater water hose.

28. DISCONNECT OUTLET HEATER WATER HOSE

Disconnect the outlet heater water hose.

29. 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.

30. 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.

31. REMOVE ECM COVER

Remove the 3 bolts and ECM cover.

NOTICE:

Remove all water from on and around the ECM cover.

Perform the inspection indoors to avoid rain.

Be sure to prevent water intrusion to the ECM (connectors and screw parts).

32. 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.

33. DISCONNECT FUEL MAIN TUBE

HINT:

34. DISCONNECT NO. 3 FUEL HOSE

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

35. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR

Remove the 4 bolts and suspension member protector.

36. 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.

37. DISCONNECT HEIGHT CONTROL SENSOR LINK

Remove the nut and disconnect the height control sensor link.

38. 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.

39. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH

HINT:

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

40. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH

Remove the 2 bolts from the front lower ball joint.

41. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH

HINT:

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

42. 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.

43. 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.

44. 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.

45. 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.

46. 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.

47. 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.

48. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

HINT:

49. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

HINT:

50. 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.

51. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

Disconnect the heated oxygen sensor connector.

Remove the 6 nuts, exhaust manifold and gasket.

52. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH

Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

Maximum warpage:
0.7 mm (0.028 in.)

HINT:

The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.).

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

53. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

Disconnect the heated oxygen sensor connector.

Remove the 6 nuts, exhaust manifold and gasket.

54. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH

Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

Maximum warpage:
0.7 mm (0.028 in.)

HINT:

The maximum allowable warpage of each installation surface is 0.3 mm (0.012 in.).

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

55. 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.

56. 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.

57. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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

58. FIX ENGINE ON ENGINE STAND

Fix the engine onto a engine stand with the bolts.

59. 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.

60. REMOVE NO. 2 ENGINE COVER

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

61. REMOVE NO. 1 ENGINE COVER

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

62. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

Remove the bolt, plate and idler pulley.

63. 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.

64. REMOVE COOLER COMPRESSOR ASSEMBLY

Disconnect the magnetic clutch connector.

Remove the 3 bolts and nut.

Remove the compressor and magnetic clutch.

65. REMOVE ENGINE MOUNTING BRACKET LH

Disconnect the 2 clamps.

Remove the 4 bolts and mounting bracket.

66. REMOVE ENGINE MOUNTING BRACKET RH

Remove the 4 bolts and mounting bracket.

67. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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

68. 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.

69. REMOVE ENGINE WIRE

Remove the engine wire from the engine.

70. REMOVE INJECTOR DRIVER

Remove the bolt, 2 nuts and injector driver.

71. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

HINT:

72. INSPECT INTAKE AIR SURGE TANK ASSEMBLY

Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.

Maximum warpage:
2.5 mm (0.098 in.)

If the warpage is greater than the maximum, replace the surge tank.

73. REMOVE NO. 2 SURGE TANK STAY

Remove the bolt and No. 2 surge tank stay.

74. REMOVE WATER HOSE JOINT

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

75. REMOVE INTAKE MANIFOLD

Disconnect the connector for the SCV.

Disconnect the SCV position sensor connector.

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

76. INSPECT INTAKE MANIFOLD

Surge tank side:

Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.

Maximum warpage:
0.1 mm (0.003 in.)

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

Cylinder head side:

Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.

Maximum warpage:
0.1 mm (0.003 in.)

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

77. REMOVE FUEL PUMP

HINT:

78. REMOVE FUEL INJECTOR ASSEMBLY

HINT:

79. REMOVE KNOCK SENSOR

Disconnect the 2 knock sensor connectors.

Remove the 2 bolts and 2 knock sensors.

80. REMOVE RADIO SETTING CONDENSER

Remove the 2 bolts and 2 radio setting condensers.

81. REMOVE V-BANK COVER BRACKET SUB-ASSEMBLY

Remove the bolt and V-bank cover bracket.

82. REMOVE IGNITION COIL ASSEMBLY

Remove the 6 bolts and 6 ignition coils.

83. REMOVE ENGINE OIL LEVEL SENSOR

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

84. REMOVE OIL PRESSURE SWITCH ASSEMBLY

Using a 24 mm deep socket wrench, remove the oil pressure switch.

85. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

Using a 19 mm deep socket wrench, remove the temperature sensor.

LEXUS IS250, IS220d / GSE20 ALE20

4GR-FSE ENGINE MECHANICAL

Lexus IS250 IS220d GSE20 ALE20

ENGINE ASSEMBLY