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

Do not allow fuel to spray when removing the pipe between the high pressure side fuel pump and the fuel injectors. The fuel in the pipe is highly pressurized.

1. REMOVE COOL AIR INTAKE DUCT SEAL

Knock Sensor - Removal. 4GR-FSE ENGINE CONTROL SYSTEM. Lexus IS250 IS220d GSE20 ALE20

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. REMOVE FRONT FENDER PROTECTOR UPPER LH

Using a clip remover, separate the clip on the rubber portion of the cowl top ventilator louver sub-assembly from the front upper fender protector LH.

Disengage the 3 clips and the claw to remove the front fender protector upper LH.

6. REMOVE FRONT FENDER PROTECTOR UPPER RH

HINT:

Removal procedure of the RH side is the same as that of the LH side.

7. REMOVE ROOF DRIP SIDE FINISH MOULDING LH

Put protective tape around the roof drip side finish moulding.

Using a moulding remover, disengage the 6 clips and remove the roof drip side finish moulding.

NOTICE:

Do not remove the clips.

If the clips are damaged or fall off, replace them with new clips.

Knock Sensor - Removal. 4GR-FSE ENGINE CONTROL SYSTEM. Lexus IS250 IS220d GSE20 ALE20

8. REMOVE ROOF DRIP SIDE FINISH MOULDING RH

HINT:

Removal procedure of the RH side is the same as that of the LH side.

9. REMOVE FRONT WIPER ARM HEAD CAP

Using a screwdriver, remove the front wiper arm head cap.

HINT:

Use the same procedures for the RH side and the LH side.

Tape the screwdriver tip before use.

10. REMOVE FRONT WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH

Remove the nut and the front wiper arm and blade assembly LH.

11. REMOVE FRONT WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH

Remove the nut and the front wiper arm and blade assembly RH.

12. DISCHARGE FUEL SYSTEM PRESSURE

HINT:

13. 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.

Knock Sensor - Removal. 4GR-FSE ENGINE CONTROL SYSTEM. Lexus IS250 IS220d GSE20 ALE20

14. REMOVE NO. 2 VENTILATION HOSE

Disconnect the ventilation hose from the cylinder head.

15. 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.

16. REMOVE THROTTLE BODY

Disconnect the throttle motor connector.

Remove the 4 bolts and disconnect the throttle body from the intake air surge tank.

Disconnect the 2 water by-pass hoses from the throttle body.

Remove the throttle body and gasket.

17. REMOVE INTAKE AIR SURGE TANK

Disconnect the vacuum hose from the intake air surge tank.

Remove the bolt and disconnect the No. 1 vacuum switching valve assembly from the intake air surge tank.

Disconnect the wire harness and hose from the surge tank.

Disconnect the ventilation hose from the intake air surge tank.

Remove the bolt and water hose joint from the intake air surge tank.

Remove the bolt and disconnect the surge tank stay.

Using a 5 mm hexagon socket wrench, remove the 7 bolts, 2 nuts and gasket.

18. 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.

19. REMOVE FUEL PRESSURE PULSATION DAMPER

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

20. 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.

21. 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:

There must be absolutely no free play in the union on the fuel pump side.

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:

Do not remove the fuel pipe from the delivery pipe. Only remove the 2 bolts.

If the No. 2 fuel pipe is accidentally removed, replace its O-ring, No. 1 backup ring and No. 2 backup ring.

22. REMOVE FUEL PUMP ASSEMBLY

Disconnect the fuel hose.

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

23. 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.

24. REMOVE NO. 3 FUEL PIPE

Remove the 4 bolts and 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. 3 fuel pipe.

25. REMOVE NO. 1 FUEL DELIVERY PIPE

Disconnect the 2 wire harness clamps.

Remove the 2 bolts and 2 nuts.

With the connectors still connected, disconnect the No. 1 fuel delivery pipe.

NOTICE:

Be extremely careful not to touch or strike the tips of the injectors.

Pull and remove the fuel pipe in a straight line without tilting it.

Disconnect the 3 connectors from the 3 injectors.

Remove the 3 injector vibration insulators from the cylinder head.

26. REMOVE NO. 2 FUEL DELIVERY PIPE

Disconnect the 3 wire harness clamps.

Remove the 2 bolts and 2 nuts.

With the connectors still connected, disconnect the delivery pipe.

NOTICE:

Make sure that the fuel delivery pipe is disconnected from the delivery pipe (LH side).

Be extremely careful not to touch or strike the tips of the injectors.

Pull and remove the fuel pipe in a straight line without tilting it.

Disconnect the 3 connectors from the 3 injectors.

Remove the 3 injector vibration insulators from the cylinder head.

27. REMOVE KNOCK SENSOR

Disconnect the 2 knock sensor connectors.

Remove the 2 bolts and 2 knock sensors.

LEXUS IS250, IS220d / GSE20 ALE20

4GR-FSE ENGINE CONTROL SYSTEM

Lexus IS250 IS220d GSE20 ALE20

KNOCK SENSOR