Lexus ES manuals

Lexus ES: Removal

Lexus ES (XZ10) Service Manual / Engine & Hybrid System / A25a-fxs (engine Mechanical) / Engine Unit / Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during engine unit removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

Auxiliary battery terminal is disconnected/reconnected

Perform steering sensor zero point calibration

Lane control system (for HV Model)

Pre-collision system (for HV Model)

Parking support brake system (for HV Model)*

Lighting system (for HV Model)

Memorize steering angle neutral point

Parking assist monitor system (for HV Model)

Panoramic view monitor system (for HV Model)

Initialize power trunk lid system

Power trunk lid system (for HV Model)

Replacement of ECM

Perform Vehicle Identification Number (VIN) registration

MIL illuminates (for HV Model)

  • Replacement of engine assembly
  • Gas leak from exhaust system is repaired
  • Replacement of throttle body with motor assembly
  • Cleaning the deposits from the throttle body assembly
  • Replacement of cam timing control motor with EDU assembly
  • Removal and installation of a cam timing control motor with EDU assembly
  • Replacement of camshaft timing gear assembly
  • Removal and installation of a camshaft timing gear assembly
  • Replacement of cylinder head sub-assembly
  • Replacement of camshaft (for intake or exhaust camshaft)
  • Replacement of camshaft timing exhaust gear assembly
  • Replacement of port fuel injector assembly
  • Replacement of direct fuel injector assembly
  • Replacement of fuel pump assembly (for high pressure side)
  • Replacement of engine coolant temperature sensor
  • Replacement of spark plug
  • Replacement of ignition coil assembly
  • Replacement of EGR valve assembly
  • Replacement of knock control sensor

Inspection After Repair
  • Poor idle, etc.
  • Engine start function, etc.

Replacement of inverter with converter assembly

Resolver learning
  • DTCs are stored
  • Slight vibration at a vehicle speed of 5 km/h (3 mph) or less
  • Shock or vibration during acceleration

Replacement of hybrid vehicle transaxle assembly
  • Resolver learning
  • Initialize resolver

Front wheel alignment adjustment
  1. Clear zero point calibration data.
  2. Perform yaw rate and acceleration sensor zero point calibration.
  • DTCs are stored
  • ABS warning light illuminates
  • Brake warning light / yellow (minor malfunction) illuminates
  • Slip indicator light illuminates
  • VSC disabled or malfunctions

  • Suspension, tires, etc.*1
  • Replacement of front bumper assembly
  • Measurement of ultrasonic sensor detection angle
  • Ultrasonic sensor detection angle registration
  • Parking support alert system
  • Parking support brake system

Suspension, tires, etc.*1

Rear television camera assembly optical axis (Back camera position setting)

Parking assist monitor system (for HV Model)

for Initialization

for Calibration

Replacement of front bumper assembly

Front television camera view adjustment

Panoramic view monitor system (for HV Model)

for Initialization

for Calibration

Suspension, tires, etc.*1
  • Parking assist ECU initialization
  • Adjust steering angle
  • Rear television camera assembly optical axis (Back camera position setting)

Replacement of headlight ECU sub-assembly LH
  • Synchronize the vehicle information
  • Perform headlight ECU sub-assembly LH initialization*2

Lighting system (for HV Model)

Suspension, tires, etc.*1

Perform headlight ECU sub-assembly LH initialization*2
  • *: When performing learning using the Techstream.

    Click here

  • *1: If the vehicle height has changed due to suspension or tire replacement.
  • *2: for LED type turn signal light

NOTICE:

  • After the power switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal. (for Audio and Visual System)
  • After the power switch is turned off, the radio receiver assembly records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal. (for Navigation System)
  • This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

    Click here

PROCEDURE

1. REMOVE DRIVE SHAFT BEARING BRACKET

(a) Remove the 3 bolts and drive shaft bearing bracket.

2. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

(a) Remove the bolt and 2 nuts.

Bolt

Nut

(b) Using an E8 "TORX" socket wrench, remove the 2 stud bolts and compressor with motor assembly.

3. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

(a) Slide the clip and disconnect the No. 2 water by-pass pipe sub-assembly from the outlet water by-pass sub-assembly.

(b) Remove the bolt and the No. 2 water by-pass pipe sub-assembly.

4. REMOVE FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

(a) Remove the bolt.

(b) Slide the clip and remove the flow shutting valve (water by-pass hose assembly) from the water by-pass outlet sub-assembly.

(c) Remove the 2 bolts and water hose clamp bracket.

5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Type A:

(1) Remove the 5 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold (TWC: Front Catalyst).

(b) Type B:

(1) Remove the 3 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold (TWC: Front Catalyst).

6. REMOVE MANIFOLD STAY

Click here

7. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst)

(a) Type A:

(1) Using a 12 mm deep socket wrench, remove the 7 nuts and exhaust manifold (TWC: Front Catalyst) from the cylinder head sub-assembly.

(b) Type B:

(1) Using a 12 mm deep socket wrench, remove the 7 nuts and exhaust manifold (TWC: Front Catalyst) from the cylinder head sub-assembly.

(c) Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.

8. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

Click here

9. REMOVE THROTTLE BODY GASKET

Click here

10. REMOVE EGR COOLER ASSEMBLY

(a) Slide the clip and disconnect the No. 4 water by-pass hose from the EGR cooler assembly.

*1

No. 3 Water By-pass Hose

*2

No. 4 Water By-pass Hose

(b) Slide the clip and disconnect the No. 3 water by-pass hose from the EGR cooler assembly.

(c) Remove the 5 bolts, EGR cooler assembly, EGR cooler gasket and EGR valve gasket.

11. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY

Click here

12. REMOVE NO. 4 WATER BY-PASS HOSE

(a) Slide the clip and remove the No. 4 water by-pass hose from the EGR valve assembly.

13. REMOVE EGR VALVE ASSEMBLY

(a) Slide the clip and disconnect the No. 8 water by-pass hose from the EGR valve assembly.

(b) for EGR Valve Bracket Connection Type:

(1) Using an 8 mm socket wrench, remove the bolt and disconnect the No. 1 fuel pipe sub-assembly from the EGR valve bracket.

(2) Using an 8 mm socket wrench, remove the bolt.

(3) Remove the EGR valve assembly vertically.

*a

Pin

*b

Hole

(c) for Cylinder Head Cover Sub-assembly Connection Type:

(1) Using an 8 mm socket wrench, remove the bolt.

(2) Remove the EGR valve assembly vertically.

*a

Pin

*b

Hole

(d) Using an 8 mm socket wrench, remove the bolt and EGR valve bracket.

14. REMOVE NO. 3 WATER BY-PASS PIPE

(a) Using an 8 mm socket wrench, remove the bolt and No. 3 water by-pass pipe from the intake manifold.

(b) Slide the clip and disconnect the No. 3 water by-pass pipe from the water outlet.

15. REMOVE NO. 2 WATER BY-PASS PIPE

(a) Remove the bolt (A).

(b) Using an 8 mm socket wrench, remove the 2 bolts (B) and No. 2 water by-pass pipe.

16. REMOVE INTAKE MANIFOLD

Click here

17. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

Click here

18. DISCONNECT FUEL TUBE SUB-ASSEMBLY

Click here

19. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) for EGR Valve Bracket Connection Type:

(1) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

(b) for Cylinder Head Cover Sub-assembly Connection Type:

(1) Using an 8 mm socket wrench, remove the bolt.

(2) Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.

20. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Click here

21. REMOVE NO. 7 WATER BY-PASS HOSE

(a) Slide the 2 clips and remove the No. 7 water by-pass hose.

22. REMOVE SENSOR WIRE

(a) Disconnect the 4 connectors.

(b) Disengage the 3 clamps.

(c) Using an 8 mm socket wrench, remove the bolt and sensor wire from the water inlet with thermostat sub-assembly.

23. REMOVE NO. 6 ENGINE WIRE

(a) Disconnect the 4 connectors.

(b) Disengage the 2 clamps.

(c) Remove the 2 nuts and No. 6 engine wire from the wire harness clamp bracket.

24. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Using an 8 mm socket wrench, remove the 2 bolts and wire harness clamp bracket from the No. 1 ventilation case.

25. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

Click here

26. REMOVE NO. 1 DELIVERY PIPE SPACER

Click here

27. REMOVE INJECTOR VIBRATION INSULATOR

Click here

28. REMOVE NO. 5 ENGINE WIRE

Click here

29. REMOVE PORT FUEL INJECTOR ASSEMBLY

Click here

30. REMOVE FUEL DELIVERY PIPE

Click here

31. REMOVE DIRECT FUEL INJECTOR ASSEMBLY

Click here

32. REMOVE IGNITION COIL ASSEMBLY

Click here

33. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Remove the engine oil level dipstick.

(b) Using an 8 mm socket wrench, remove the bolt and engine oil level dipstick guide from the camshaft housing sub-assembly.

(c) Remove the O-ring from the engine oil level dipstick guide.

34. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

(a) Type A:

(1) Remove the bolt and No. 3 exhaust manifold heat insulator from the cylinder block sub-assembly.

(b) Type B:

(1) Remove the 2 bolts and No. 3 exhaust manifold heat insulator from the cylinder block sub-assembly.

READ NEXT:

 Disassembly

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REASSEMBLY CAUTION / NOTICE / HINT NOTICE: This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts. Click here P

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