Engine Oil Cooler Removal

Engine. Lexus Is250, Is220D. Gse20 Ale20
2Ad-Fhv Lubrication. Lexus Is250, Is220D. Gse20 Ale20

  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  2. REMOVE NO. 1 ENGINE COVER

  3. REMOVE NO. 1 INLET AIR CLEANER

  4. REMOVE ENGINE ROOM SIDE COVER LH

  5. DRAIN ENGINE COOLANT

  6. REMOVE WIRE HARNESS CLAMP BRACKET

  7. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY

  8. REMOVE EGR VALVE ASSEMBLY

  9. REMOVE NO. 1 WATER OUTLET PIPE

  10. REMOVE AIR PIPE SUB-ASSEMBLY

  11. REMOVE NO. 4 AIR HOSE

  12. REMOVE DIESEL THROTTLE BODY

  13. REMOVE NO. 1 FUEL PIPE

  14. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY

  15. REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY

  16. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY

  17. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY

  18. REMOVE INLET FUEL PIPE SUB-ASSEMBLY

  19. REMOVE COMMON RAIL ASSEMBLY

  20. REMOVE INTAKE MANIFOLD STAY

  21. REMOVE INTAKE MANIFOLD SUB-ASSEMBLY

  22. REMOVE OIL COOLER ASSEMBLY

  23. REMOVE NO. 1 TURBO OIL PIPE

  24. REMOVE NO. 1 OIL COOLER BRACKET

  25. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

Engine Oil Cooler -- Removal



1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL


2. REMOVE NO. 1 ENGINE COVER


    Lexus Is250, Is220D. Gse20 Ale20

  1. Remove the No. 1 engine cover.



3. REMOVE NO. 1 INLET AIR CLEANER


    Lexus Is250, Is220D. Gse20 Ale20

  1. Remove the bolt, clip and inlet air cleaner.



4. REMOVE ENGINE ROOM SIDE COVER LH


    Lexus Is250, Is220D. Gse20 Ale20

  1. Remove the 4 clips and side cover.



5. 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.

  1. Remove the radiator cap.



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


    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

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


6. REMOVE WIRE HARNESS CLAMP BRACKET


    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

  1. Disconnect the wiring harness clamp.



    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

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

  1. Disconnect the EGR valve connector (*2).

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



    Lexus Is250, Is220D. Gse20 Ale20

  1. Remove the 2 bolts and wire harness clamp bracket.



7. REMOVE NO. 2 EGR PIPE SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

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



8. REMOVE EGR VALVE ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

  1. Remove the 2 bolts, EGR valve assembly and gasket.



9. REMOVE NO. 1 WATER OUTLET PIPE


    Lexus Is250, Is220D. Gse20 Ale20

  1. Disconnect the manifold absolute pressure sensor connector and vacuum hose.



    Lexus Is250, Is220D. Gse20 Ale20

  1. Remove the insulator.



    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

  1. Disconnect the 2 water hoses.

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



10. REMOVE AIR PIPE SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

  1. Disconnect the 2 diesel throttle body connectors.



    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

  1. Loosen the 3 hose bands.

  1. Disconnect the intake air temperature sensor connector.



    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

  1. Remove the bolt and air pipe sub-assembly.

  1. Disconnect the wire harness clamp.



11. REMOVE NO. 4 AIR HOSE


12. REMOVE DIESEL THROTTLE BODY


    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

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



13. REMOVE NO. 1 FUEL PIPE


    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

  1. Loosen the 2 clips and disconnect the 2 fuel hoses.

  1. Remove the 2 bolts and the No. 1 fuel pipe.



14. REMOVE NO. 1 INJECTION PIPE SUB-ASSEMBLY
NOTICE:
After removing the fuel pipe, cover the common rail with electrical tape to prevent dirt or foreign objects from entering the pipe inlet. Also protect the injector inlets with electrical tape or plastic bags.


    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

  1. Remove the 2 bolts and 4 injection pipe clamps.

  1. Using the SST, loosen the nut at the common rail end of the injection pipe.

    SST
    09023-38401

  1. Using the SST, loosen the nut at the injector end of the injection pipe.

    SST
    09023-38401

  1. Remove the No. 1 injection pipe sub-assembly.



15. REMOVE NO. 2 INJECTION PIPE SUB-ASSEMBLY
HINT:
Perform the same procedure as for the No. 1 injection pipe.


16. REMOVE NO. 3 INJECTION PIPE SUB-ASSEMBLY
HINT:
Perform the same procedure as for the No. 1 injection pipe.


17. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY
HINT:
Perform the same procedure as for the No. 1 injection pipe.


18. REMOVE INLET FUEL PIPE SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20

  1. Remove the bolt and 2 injection pipe clamps.

  1. Using the SST, loosen the nut at the common rail end of the fuel inlet pipe.

    SST
    09023-38401

  1. Using the SST, loosen the nut at the supply pump end of the fuel inlet pipe.

    SST
    09023-38401

  1. Remove the 2 fuel inlet pipe sub-assemblies.



19. REMOVE COMMON RAIL ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

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

  1. Disconnect the fuel hose.

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



    Lexus Is250, Is220D. Gse20 Ale20

  1. Remove the 2 bolts and the common rail assembly.



20. REMOVE INTAKE MANIFOLD STAY


    Lexus Is250, Is220D. Gse20 Ale20

  1. Remove the 2 bolts and intake manifold stay.



21. REMOVE INTAKE MANIFOLD SUB-ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20

  1. Remove the 7 bolts, 2 nuts and intake manifold sub-assembly.

  1. Remove the intake manifold gasket from the cylinder head.



22. REMOVE OIL COOLER ASSEMBLY

  1. Loosen the clip and disconnect the water by-pass hose.



    Lexus Is250, Is220D. Gse20 Ale20

  1. Remove the 5 bolts and oil cooler assembly.

  1. Remove the 3 O-rings from the No. 1 oil cooler bracket.



23. REMOVE NO. 1 TURBO OIL PIPE


    Lexus Is250, Is220D. Gse20 Ale20

  1. Remove the 2 bolts and No. 3 water by-pass pipe.

  1. Remove the O-ring from the No. 3 water by-pass pipe.



    Lexus Is250, Is220D. Gse20 Ale20

  1. Remove the 2 union bolts, 2 gaskets and No. 1 turbo oil pipe.



24. REMOVE NO. 1 OIL COOLER BRACKET


    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

  1. Remove the 6 bolts, nut and No. 1 oil cooler bracket.

  1. Remove the 3 O-rings from the No. 1 oil cooler bracket.



25. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    Lexus Is250, Is220D. Gse20 Ale20.2Ad-Fhv Lubrication.Lubrication System.Engine Oil Cooler Removal

  1. Remove the oil pressure switch assembly from the No. 1 oil cooler bracket.