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Home >> Lexus >> 2023 >> ES 300h Base >> Repair and Diagnosis >> External Pages >> Different car >> Section 34 (Engine Mechanical System (2GR-FKS) - Service Information (2 Of 3)) >> Engine Assembly >> Removal [10/2019 - 08/2021] >> Procedure

Removal [10/2019 - 08/2021]: Procedure

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  1. PRECAUTION 
    NOTE:

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  3. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [06/2018 - ]

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 

    Refer to PROCEDURE - Step 1

  5. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  6. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 3 [10/2019 - 08/2020] , or refer to PROCEDURE - Step 3 [08/2020 - 08/2021]

  7. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 
    1. Remove the 3 screws and front wheel opening extension pad LH.
  8. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 
    1. Remove the 3 screws and front wheel opening extension pad RH.
  9. REMOVE NO. 1 ENGINE UNDER COVER 
    1. Remove the bolt, 2 clips, 6 screws and No. 1 engine under cover.
  10. REMOVE NO. 3 ENGINE UNDER COVER 
    1. Remove the 2 screws, 3 clips and No. 3 engine under cover.
  11. REMOVE NO. 2 ENGINE UNDER COVER 
    1. Remove the 2 screws, 3 clips and No. 2 engine under cover.
  12. REMOVE FRONT FENDER APRON SEAL LH 
    1. Remove the 2 screws, clip and front fender apron seal LH from the vehicle body.
  13. REMOVE FRONT FENDER APRON SEAL RH 
    1. Remove the 2 screws, clip and front fender apron seal RH from the vehicle body.
  14. REMOVE FRONT BUMPER COVER 

    Refer to REMOVAL [06/2018 - 08/2021]

  15. REMOVE FRONT LOWER BUMPER ABSORBER 
    1. Remove the 4 bolts.
      GTY821820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 claws to remove the front lower bumper absorber.
  16. DRAIN ENGINE COOLANT 

    Refer to PROCEDURE - Step 1

  17. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 5

  18. DRAIN AUTOMATIC TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 7 [06/2018 - 01/2020] , or refer to PROCEDURE - Step 7 [01/2020 - 08/2020] , or refer to PROCEDURE - Step 7 [08/2020 - 08/2021]

  19. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Disengage the 4 clips in the order shown in the illustration and lift the V-bank cover sub-assembly upward to remove it.
      Fig 1: V-Bank Cover Sub-Assembly Clip Removal Sequence [10/2019 - 08/2021]
      GTY811979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Hold here Pull in this Direction
      NOTE:
      • Pull the V-bank cover sub-assembly straight up to remove it.
      • Do not remove the V-bank cover sub-assembly in any direction other than upward. If the V-bank cover sub-assembly is removed in any direction other than upward, it may be damaged.
      • If the clips are not disengaged in the order shown in the illustration, the V-bank cover sub-assembly may be damaged.
  20. REMOVE INLET AIR CLEANER ASSEMBLY 
    1. Remove the 2 bolts and inlet air cleaner assembly.
      GTY806605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 
    1. Disengage the 2 clamps to disconnect the No. 1 fuel vapor feed hose from the air cleaner hose.
      GTY741891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Fuel Vapor Feed Hose
      *2 No. 2 Ventilation Hose
    2. Slide the clip and disconnect the No. 2 ventilation hose from the air cleaner hose.
    3. Loosen the hose clamp.
      GTY774129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the mass air flow meter sub-assembly connector.
      GTY819422Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
    5. Disengage the 3 wire harness clamps.
    6. Disconnect the vacuum hose from the air cleaner hose.
    7. Disengage the 3 pins and remove the air cleaner assembly with air cleaner hose.
      NOTE:

      Make sure the air cleaner support remains attached to the vehicle body.

  22. REMOVE ECM 

    Refer to PROCEDURE - Step 6

  23. DISCONNECT ENGINE ROOM MAIN WIRE 
    1. Remove the nut and disconnect the engine wire with engine room main wire from the positive (+) battery terminal.
      GTY766939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE BATTERY 

    Refer to PROCEDURE - Step 2

  25. REMOVE BATTERY CLAMP SUB-ASSEMBLY 
    1. Disengage the 5 clamps from the battery clamp sub-assembly.
      GTY749840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and battery clamp sub-assembly.
  26. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. While disengaging the clip as shown in the illustration, disconnect the transmission control cable assembly from the transmission control shaft lever together with the clip.
      GTY761119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clip
      *b 45° to 60°
    2. Remove the clip and disconnect the transmission control cable assembly from the No. 1 transmission control cable bracket.
      GTY745940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Slide the clip and disconnect the No. 1 fuel vapor feed hose from the No. 1 vacuum switching valve assembly.
      GTY812850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Slide the clip and disconnect the union to check valve hose from the brake booster assembly.
      GTY749850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.
      GTY821817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. SEPARATE RADIATOR HOSE SUB-ASSEMBLY 
    1. Slide the clip and disconnect the radiator hose sub-assembly from the water outlet.
      GTY749823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and separate the radiator hose sub-assembly from the engine assembly.
  31. DISCONNECT INLET HEATER WATER HOSE 
    1. Disengage the clamp.
      GTY770567Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the inlet heater water hose from the water outlet.
  32. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Slide the clip and disconnect the outlet heater water hose from the heater water pipe.
      GTY749848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. DISCONNECT NO. 1 FUEL HOSE 
    1. Disengage the 2 claws to remove the No. 2 fuel pipe clamp.
      GTY773653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 1 fuel pipe clamp from the fuel tube connector.
      GTY739823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the No. 1 fuel hose (for Port Injection).
      1. Disconnect the No. 1 fuel hose from the fuel pipe.

        Refer to PRECAUTION [06/2018 - ]

        GTY812849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the No. 1 fuel hose (for Direct Injection).
      1. Disconnect the No. 1 fuel hose from the fuel pipe.
        GTY812846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Refer to PRECAUTION [06/2018 - ]

    5. Separate the bolt and disengage the No. 1 fuel hose.
      GTY781240Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 4

  35. DISCONNECT SUCTION HOSE 

    Refer to PROCEDURE - Step 5

  36. DISCONNECT ENGINE WIRE 

    HINT: 

    After disconnecting the engine wire, secure it with tape or equivalent to keep it out of the way.

    1. Remove the No. 2 relay block cover from the engine room relay block and junction block assembly.
      GTY821821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut from the engine room relay block and junction block assembly.
      GTY821836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the 4 connectors from the engine room relay block and junction block assembly.
    4. Disengage the 2 clamps.
    5. Using a screwdriver, disengage the claw and disconnect the engine wire from the engine room relay block and junction block assembly.
    6. Remove the bolt.
      GTY821834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disengage the clamp and disconnect the engine wire from the vehicle body.
  37. DISCONNECT EARTH WIRE 
    1. Remove the 2 bolts and disconnect the earth wire from the vehicle body.
      GTY766938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 11 [10/2019 - 08/2020] , or refer to PROCEDURE - Step 11 [08/2020 - 08/2021]

  39. REMOVE EXHAUST MANIFOLD 

    Refer to REMOVAL [06/2018 - ]

  40. REMOVE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to REMOVAL [06/2018 - ]

  41. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Upper Side) 
    1. Remove the 2 bolts and No. 1 exhaust pipe support bracket from the oil pan sub-assembly.
      GTY749842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the 2 bolts and flywheel housing under cover.
      GTY686606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 

    Refer to PROCEDURE - Step 2

  44. REMOVE SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper) 

    Refer to PROCEDURE - Step 4 [06/2018 - 08/2020] , or refer to PROCEDURE - Step 4 [08/2020 - ]

  45. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set an engine lifter.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle level.
      • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
      • To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.
      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments under the No. 2 oil pan sub-assembly of the engine assembly with transaxle.
    2. Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.
      GTY766319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 bolts and nut and separate the engine mounting insulator sub-assembly RH from the front No. 1 engine mounting bracket LH.
      GTY749844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and nut and separate the engine mounting insulator LH from the engine mounting bracket sub-assembly LH.
      GTY749845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. w/o Suspension Tower Damper:
      GTY836467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
      1. Remove the 8 bolts and front bumper extension sub-assembly RH and front bumper extension sub-assembly LH from the front frame assembly and vehicle body.
      2. Remove the 4 bolts, 2 nuts and front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH from the front frame assembly and vehicle body.
    6. w/ Suspension Tower Damper:
      GTY821572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
      1. Remove the 6 bolts and front bumper extension sub-assembly RH and front bumper extension sub-assembly LH from the front frame assembly and vehicle body.
      2. Remove the 4 bolts, 2 nuts and front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH from the front frame assembly and vehicle body.
    7. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.
      NOTE:
      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
      • While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.
  46. DISCONNECT VACUUM HOSE 

    Refer to PROCEDURE - Step 4

  47. REMOVE STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 9

  48. REMOVE BREATHER PLUG HOSE 

    Refer to PROCEDURE - Step 6

  49. DISCONNECT NO. 1 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 7

  50. DISCONNECT WATER BY-PASS HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 8

  51. REMOVE ENGINE WIRE 
    1. Disconnect all clamps and connectors and remove the engine wire from the engine assembly with transaxle.
  52. INSTALL ENGINE HANGERS 
    1. Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.

      Torque: 33 N.m (337 kgf/cm, 24 ft.lbf) 

      HINT: 

      No. 1 Engine Hanger 12281-31121
      No. 2 Engine Hanger 12282-31100
      Bolt 90119-A0117
      GTY732836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1
      *B for Bank 2
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
    2. Using an engine sling device and engine lifter, secure the engine assembly with transaxle.
      NOTE:
      • Adjust the angle of the sling device carefully to prevent damage or deformation to the engine hangers or engine assembly.
      • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
  53. REMOVE FRONT FRAME ASSEMBLY 
    1. Remove the bolt and separate the front engine mounting insulator from the front engine mounting bracket.
      GTY743458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts and separate the rear engine mounting insulator from the front frame assembly.
      GTY756943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the front engine mounting insulator is necessary.

    1. Remove the 3 nuts and front engine mounting insulator from the front frame assembly.
      GTY769145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE REAR ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

    Refer to PROCEDURE - Step 2

  56. REMOVE FRONT ENGINE MOUNTING BRACKET 

    Refer to PROCEDURE - Step 12

  57. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 13

  58. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  2

  59. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 

    See step  3

  60. INSTALL ENGINE ASSEMBLY TO ENGINE STAND 
    1. Install the engine assembly to an engine stand.
  61. REMOVE ENGINE HANGERS 
    1. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and cylinder head LH.
  62. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

    1. Disengage the clamp.
      GTY821838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, nut and separate the radiator reserve tank assembly.
    3. Remove the bolt and separate the bracket from the engine mounting insulator sub-assembly RH.
      GTY770568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the clamp.
      GTY754442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the nut, 2 bolts and engine mounting insulator sub-assembly RH from the engine mounting spacer and vehicle body.
  63. REMOVE ENGINE MOUNTING SPACER 

    HINT: 

    Perform this procedure only when replacement of the engine mounting spacer is necessary.

    1. Remove the 2 bolts and engine mounting spacer from the vehicle body.
      GTY783909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting bracket sub-assembly LH is necessary.

    1. Remove the 4 bolts and engine mounting bracket sub-assembly LH from the vehicle body.
      GTY829203Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE ENGINE MOUNTING INSULATOR LH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

    Refer to PROCEDURE - Step 14

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