TECHNICAL INSTRUCTIONS

FOR

SPECIAL SERVICE CAMPAIGN 22LC02
Crankcase Case Vent

Certain 2022 Model Year ES300h
Certain 2022 Model Year ES250

The repair quality of covered vehicles is extremely important to Lexus. All dealership technicians
performing this special service campaign are required to successfully complete the most current
version of the E-Learning course “Safety Recall and Service Campaign Essentials”. To ensure
that all vehicles have the repair performed correctly; technicians performing this special service
campaign repair are required to currently have completed all of the following courses:
L151 – Engine Service and Repair
It is the dealership’s responsibility to select technicians that have completed the above courses
to perform this campaign repair. Carefully review your resources, the technician skill level, and
ability before assigning technicians to this repair. It is important to consider technician days off
and vacation schedules to ensure there are properly trained technicians available to perform this
repair at all times.

OPERATION FLOW CHART

Verify Vehicle Eligibility
1. Confirm vehicle VIN matches the RO.
2. Check for Campaign eligibility using TIS.

Not
Covered

No further action required.

Covered

Inspect Vacuum Pressure at No. 2 PCV Hose

Did the PCV System operate as intended?

PCV Ok Condition

PCV NG Condition
Remove and Replace PCV No. 1 Ventilation
Case

Reassemble vehicle with new Gasket Kits

Campaign complete.
Return the vehicle to the customer.

2

I.

IDENTIFICATION OF AFFECTED VEHICLES

1. CHECK VEHICLE FOR CAMPAIGN ELIGIBILITY
a. Compare the vehicle’s VIN to the VIN listed on the Repair Order to ensure they match.
b. Check the TIS Vehicle Inquiry System to confirm the VIN is involved in this Campaign, and
that it has not already been completed.
Note: TMNA warranty will not reimburse dealers for repairs completed on vehicles that are
not affected or were previously completed, even by another dealer.

II. PREPARATION
A. PARTS – Vehicles with an NG Operating Case Vent will require a combination of 2 part
numbers. Each Vehicle will require No. 1 Ventilation Case Kit – 04002-08325 and 1 of the 2
gasket kits, see table below for applicability.
Model
Fits all 22LC02
Vehicles

Part Number

Quantity

04002-08325

1

Description
Crankcase Case Vent Kit*

*The kit above includes the following part.
Part Description
Quantity
Remarks
No. 1 Ventilation Case
1
-

Model
ES300h

Part Number
Quantity Description
04002-08225
1
Gasket Kit for: ES300h (Hybrid)
*The kit above includes the following parts.
Part Description
Quantity
Remarks
Oil Separator Gasket
3
Intake Manifold Gasket
1
EGR Inlet Gasket
1
EGR Valve Adapter Gasket
1
Local Part No.:
Throttle Body Gasket
1
22271-F0020

Model
ES250

Part Number
Quantity Description
04002-08125
1
Gasket Kit for: ES250 (Conventional Gasoline)
*The kit above includes the following parts.
Part Description
Quantity
Remarks
Oil Separator Gasket
3
Intake Manifold Gasket
1
EGR Inlet Gasket
1
EGR Valve Adapter Gasket
1
Local Part No.:
Throttle Body Gasket
1
22271-F0010

Warranty will only reimburse dealers for the part numbers listed. Any other part numbers will not be
accepted on the campaign claim.

3

B. Tools and Equipment
• Standard Hand Tools
• Socket Wrench 8mm
• Mirror

• Techstream
• Deep Socket Wrench 8mm
• Camera

• Torque Wrench
• “TORX” Socket Wrench E-type E8

• Protective Gloves
• Balloon

• Cloth
• Plastic Bag (if balloon is not
available)

C. Materials
• Protective Tape
• Tape
• Marker Pen

III. BACKGROUND
The subject vehicles may have been equipped with an engine containing an incorrectly
manufactured Crankcase Case Vent. If the engine is equipped with an incorrectly manufactured
Crankcase Case Vent, the vehicle may not comply with certain Federal emissions regulations.

IV. WORK PROCEDURE TABLE OF CONTENTS
COMPONENTS ························································································ SECTION V
INSPECT VACUUM PRESSURE OF NO. 2 PCV HOSE ··································· SECTION VI
REMOVE NO. 1 VENTILATION CASE ························································ SECTION VII
INSTALL NEW NO. 1 VENTILATION CASE ················································ SECTION VIII
APPENDIX ····························································································· SECTION IX

4

V.

COMPONENTS
A.

Components if the inspection is OK – ES300h and ES250

B. Components if the inspection is NG – ES300h

5

C.

Components if the inspection is NG – ES250

6

VI.

INSPECT VACUUM PRESSURE OF NO. 2 PCV HOSE
1. Disconnect No. 2 PCV Hose
a. Use Squeezing motion on clip handles to slide clip up No.
2 PCV hose and remove hose from air cleaner hose.

2. Install Balloon for Testing
a. Use tape (painters tape, masking tape, electrical tape,
etc.) to seal port on air cleaner hose.
NOTE: It is important that tape seals the port completely. A
port that allows un metered air to enter the engine may set a
malfunction indicator light (MIL).
b. Attach a balloon over No. 2 PCV hose. Use clip to secure
balloon tightly over No. 2 PCV hose. If a balloon is not
available, a small plastic bag be used in place of a balloon.
NOTE: It is important that the balloon or plastic bag seals
tightly around No. 2 PCV hose. If there is not a tight seal
around the hose, the inspection will not be performed
correctly.
3. Vacuum Pressure Test – Gasoline and Hybrid Engines
a. Start the vehicles engine and allow the vehicle to idle for 15-20 seconds.
Do NOT allow the engine to idle for more than 20 seconds. Damage will occur
to the engine oil seals.
Note: For hybrid vehicles, engines can be started by depressing the accelerator pedal
quickly 2-3 times or using inspection mode.
Refer to TIS for instructions on General / INTRODUCTION / REPAIR INSTRUCTION /
INSPECTION MODE PROCEDURE
b. Stop the vehicles engine after 15-20 seconds of idle and observe the condition of the balloon.
c. Use the inspection results chart below (page 8) to determine next steps.
d. Remove tape from air cleaner port previously taped.
e. Remove the balloon assembly or bag from PCV hose NO.
2 and reintall hose on air cleaner port. Slide spring clip
over hose port connection.

7

PCV Vacuum Pressure Test Inspection Results
Example Condition

Next Steps
• Confirm No. 2 PCV hose has been
reinstalled on air cleaner hose fitting.

OK Condition –
Balloon or bag
experiences some
shrinkage due to vacuum
(Or no visible change).

• Campaign complete. Return vehicle to
customer.

NG Condition -

• Continue to Section VII – Remove No. 1
Ventilation Case.

Balloon or bag
experiences inflation /
expansion from positive
pressure.

VII.

REMOVE NO. 1 VENTILATION CASE
1. CHECK FOR DTC’S
a) Perform a Health Check to check for Diagnostic
Trouble Codes.
NOTE: This campaign covers only the replacement
of No. 1 ventilation case and associated parts. It does
not cover the diagnosis or replacement of any other
parts on the vehicle.
2. RECORD CUSTOMER SETTINGS
a) When the battery cable is disconnected, the
settings for the audio, air conditioning etc., may
be reset. Make a note of the settings before
disconnecting the cable from the negative (-)
battery terminal.
3. DISCONNECT CABLE FROM BATTERY
NEGATIVE TERMINAL

8

4. REMOVE FOLLOWING COMPONENTS
• Cool air intake duct seal
• Air cleaner cap with air

cleaner hose

• Inlet air cleaner assembly
• Air cleaner filter element

• No. 1 engine cover sub-

assembly

sub-assembly

9

5. SEPARATE THROTTLE BODY ASSEMBLY
a) Disconnect the throttle body assembly connector.
b) Using an 8 mm deep socket wrench, remove the
3 bolts and disconnect the throttle body
assembly from the intake manifold.
Do NOT disconnect the water bypass hose
Remove the throttle body gasket from the intake
manifold.
NOTE: The shape of throttle body gasket differs
between ES300h and ES250 vehicles.
c)

d)

Cut the removed throttle body gasket to avoid
confusion with new part and or reinstallation on
the vehicle.

6. SEPARATE NO. 2 WATER BY-PASS PIPE
a) ES300h:
1) Using an 8 mm socket wrench, remove the 2
bolts and separate the No. 2 water by-pass
pipe from the intake manifold.
Do NOT disconnect the water bypass hose from metal pipe.
b)

ES250:
1) Using an 8 mm socket wrench, remove the 2
bolts (A) and disconnect the No. 2 water bypass pipe from the intake manifold.
2) Remove the bolt (B) and No. 2 water by-pass
pipe from the cylinder block assembly.
Do NOT disconnect the water bypass hose from metal pipe.

7. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE
a) Disconnect the No. 2 fuel vapor feed hose from
the intake manifold.

10

8. REMOVE FUEL DELIVERY GUARD
a) Remove the bolt and fuel delivery guard from the
engine mounting bracket RH.

9. DISCONNECT ENGINE WIRE
a) ES300h:
1) Disconnect the 3 connectors.
2) Remove the 2 bolts.
3) Disengage the 2 wire harness clamps and
disconnect the engine wire.

b)

ES250:
1) Disengage the hose clamp and disconnect the
No. 5 water by-pass hose. (Only for CAMRY)
2) Disconnect the 3 connectors.
3) Remove the 2 bolts.
4) Disengage the 2 wire harness clamps and
disconnect the engine wire.

10. SEPARATE NO. 3 WATER BY-PASS PIPE
a) Using an 8 mm socket wrench, remove the bolt
and disconnect the No. 3 water by-pass pipe
from the intake manifold.
Do NOT disconnect the water bypass hose from by-pass pipe.

11

11. SEPARATE PURGE VALVE (PURGE VSV)
For ES300h:
a) Remove the bolt and purge valve (purge VSV)
from the purge VSV bracket.

12. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY
a) Using an 8 mm socket wrench, remove the 4
bolts and No. 1 EGR pipe assembly from the
intake manifold and EGR valve.

b)

Remove the EGR valve adapter gasket from the
No. 1 EGR pipe assembly.

c)

Cut the removed EGR valve adapter gasket to
avoid confusion with new part and or
reinstallation on the vehicle.

d)

Remove the EGR inlet gasket from the intake
manifold.

e)

Cut the removed EGR inlet gasket to avoid
confusion with new part and or reinstallation on
the vehicle.

13.
a)
b)
c)

DISCONNECT ENGINE WIRE
Disconnect the 2 connectors.
Remove the bolt.
Disengage the wire harness clamp and
disconnect the engine wire from the intake
manifold.

12

14. DISCONNECT NO. 5 ENGINE WIRE
a) Disengage the wire harness clamp and
disconnect the No. 5 engine wire.

15. REMOVE INTAKE MANIFOLD
a) Without Stud Bolt:
1) Remove the 5 bolts.
b) With Stud Bolt:
1) Remove the 3 bolts and 2 nuts.
2) Using an E8 "TORX" socket wrench, remove
the 2 stud bolts.
c) Pull the intake manifold toward the vehicle front
and then disconnect the fuel pressure sensor
connector.
• NOTE: The fuel pressure sensor connector may be
damaged by contacting the intake manifold during
removal, disconnect the fuel pressure sensor
connector before removing the intake manifold.
• NOTE: The O-ring of PCV valve may be damaged
if the intake manifold is removed diagonally, pull
the intake manifold straight toward you to avoid
damaging PCV.

d)
e)

Clean the opening of the cylinder head where the
intake ports are located.
To prevent contamination from foreign material,
apply protective tape (painters tape or masking
tape) to the opening of the cylinder head intake
ports.

f)

Remove the No. 1 intake manifold to head
gasket from the intake manifold.