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Engine Cooling System (Service Information): Removal & Installation Lexus CT I

Cooling Fan 37 illustrations ~2555 words

INSTALLATION

  1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Using a union nut wrench (19 mm), install the engine coolant temperature sensor. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) NOTE: Do not apply any excessive force to the heater pipe when installing the engine coolant temperature sensor. Connect the connector.
  2. ADD COOLANT (for Engine) See step 2
  3. INSPECT FOR COOLANT LEAK (for Engine) . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-568726-S04853020212013072300000)
  4. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 98»(ref-568735-S28791889062013072300000)

Scheme 14

Scheme 14: ILLUSTRATION
Scheme 14: ILLUSTRATION

Scheme 15

Scheme 15: REMOVAL
Scheme 15: REMOVAL

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17
  1. REMOVE RADIATOR SUPPORT OPENING COVER . Refer to «REMOVAL - Step 1»(ref-568749-S05660375792013072300000)
  2. REMOVE INLET AIR CLEANER ASSEMBLY . Refer to «REMOVAL - Step 5»(ref-568740-S42718219202013072300000)
  3. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to «REMOVAL - Step 4»(ref-568735-S10086557472013072300000)
  4. DRAIN COOLANT (for Engine) See step 1
  5. REMOVE WATER INLET WITH THERMOSTAT SUB-ASSEMBLY Disconnect the No. 2 radiator hose and No. 3 water by-pass hose. TEXT IN ILLUSTRATION *1 No. 2 Radiator Hose *2 No. 3 Water By-pass Hose NOTE: Do not apply force to the water inlet with thermostat sub-assembly when disconnecting the No. 3 water by-pass hose. Do not damage the water inlet with thermostat sub-assembly. HINT: When disconnecting the No. 3 water by-pass hose, pinch the hose clamp, rotate the hose and pull it straight off the pipe. Remove the 2 nuts, bolt and water inlet with thermostat sub-assembly. Remove the gasket from the water inlet with thermostat sub-assembly.

Scheme 18

Scheme 18: INSPECTION
Scheme 18: INSPECTION

Scheme 19

Scheme 19
Scheme 19
  1. INSPECT WATER INLET WITH THERMOSTAT SUB-ASSEMBLY Immerse the water inlet with thermostat sub-assembly in water and then gradually heat the water. Check the valve opening temperature of the water inlet with thermostat sub-assembly. Valve opening temperature 80 to 84°C (176 to 183°F) HINT: If the valve opening temperature is not as specified, replace the water inlet with thermostat sub-assembly. Check the valve lift. TEXT IN ILLUSTRATION *a 10 to 14 mm Valve lift 10 to 14 mm (0.394 to 0.551 in.) at 95°C (203°F) HINT: If the valve lift is not as specified, replace the water inlet with thermostat sub-assembly. Check that the valve is fully closed when the water inlet with thermostat sub-assembly is at low temperatures (below 77°C (171°F)). HINT: If it is not fully closed, replace the water inlet with thermostat sub-assembly.
  1. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY Install a new gasket on the water inlet with thermostat sub-assembly. Install the water inlet with thermostat sub-assembly with the 2 nuts and bolt. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) Connect the No. 2 radiator hose and No. 3 water by-pass hose.
  2. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE . Refer to «INSTALLATION - Step 14»(ref-568735-S20848597852013072300000)
  3. INSTALL INLET AIR CLEANER ASSEMBLY . Refer to «INSTALLATION - Step 4»(ref-568740-S13944941502013072300000)
  4. ADD COOLANT (for Engine) See step 2
  5. INSPECT FOR COOLANT LEAK (for Engine) . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-568726-S04853020212013072300000)
  6. INSTALL RADIATOR SUPPORT OPENING COVER . Refer to «INSTALLATION - Step 3»(ref-568749-S42200779382013072300000)

Scheme 20

Scheme 20: ILLUSTRATION
Scheme 20: ILLUSTRATION

Scheme 21

Scheme 21: REMOVAL
Scheme 21: REMOVAL
  1. REMOVE FRONT EXHAUST PIPE ASSEMBLY Refer to «REMOVAL»(ref-568745-S07351275932013072300000)
  2. DRAIN COOLANT (for Engine) See step 1
  3. REMOVE EXHAUST PIPE GAS CONTROL ACTUATOR SUB-ASSEMBLY Remove the 5 bolts and exhaust pipe gas control actuator sub-assembly with the exhaust by-pass pipe installed. NOTE: When removing the exhaust pipe gas control actuator sub-assembly, use caution because coolant may spill out from the exhaust heat recirculation system. Do not apply any excessive force to the exhaust by-pass pipe when removing the exhaust pipe gas control actuator sub-assembly. Remove the exhaust by-pass pipe from the exhaust pipe gas control actuator sub-assembly.

Scheme 22

Scheme 22: INSTALLATION
Scheme 22: INSTALLATION
  1. INSTALL EXHAUST PIPE GAS CONTROL ACTUATOR SUB-ASSEMBLY Install the exhaust by-pass pipe to the exhaust pipe gas control actuator sub-assembly. NOTE: When reusing the exhaust by-pass pipe, inspect the O-ring. If the O-ring has scratches or cuts, replace the exhaust by-pass pipe. Install the exhaust pipe gas control actuator sub-assembly and exhaust by-pass pipe with the 5 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) NOTE: Do not apply any excessive force to the exhaust by-pass pipe when installing the exhaust pipe gas control actuator sub-assembly.
  2. INSTALL FRONT EXHAUST PIPE ASSEMBLY Refer to «INSTALLATION»(ref-568745-S32300714722013072300000)
  3. ADD COOLANT (for Engine) See step 2
  4. INSPECT FOR COOLANT LEAK (for Engine) . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-568726-S04853020212013072300000)

Scheme 23

Scheme 23: ILLUSTRATION
Scheme 23: ILLUSTRATION

Scheme 24

Scheme 24: ON-VEHICLE INSPECTION
Scheme 24: ON-VEHICLE INSPECTION

Scheme 25

Scheme 25
Scheme 25
  1. INSPECT COOLING FAN MOTOR Check that the motor operates smoothly when the battery is connected to the cooling fan motor connector. TEXT IN ILLUSTRATION *a Component without harness connected (Cooling Fan Motor) Clamp the 400 A probe of an ammeter over the (+) wire of the cooling fan motor. Measure the current while the motor is operating. Standard Current Item Condition Specified Condition Cooling fan motor 20°C (68°F) 4.7 to 8.7 A at 12 V If the result is not as specified, replace the cooling fan motor.
  2. INSPECT NO. 2 COOLING FAN MOTOR Check that the motor operates smoothly when the battery is connected to the No. 2 cooling fan motor connector. TEXT IN ILLUSTRATION *a Component without harness connected (No. 2 Cooling Fan Motor) Clamp the 400 A probe of an ammeter over the (+) wire of the No. 2 cooling fan motor. Measure the current while the motor is operating. Standard Current Item Condition Specified Condition No. 2 cooling fan motor 20°C (68°F) 4.7 to 8.7 A at 12 V If the result is not as specified, replace the No. 2 cooling fan motor.

Scheme 26

Scheme 26: REMOVAL
Scheme 26: REMOVAL

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30
  1. REMOVE RADIATOR ASSEMBLY HINT: Refer to «REMOVAL»(ref-568743-S10843884182013072300000)
  2. REMOVE NO. 2 FAN Remove the nut and No. 2 fan.
  3. REMOVE FAN Remove the nut and fan.
  4. REMOVE NO. 2 COOLING FAN MOTOR Remove the 3 screws and No. 2 cooling fan motor.
  5. REMOVE COOLING FAN MOTOR Disconnect the 5 clamps. NOTE: Be careful not to damage the connector. Remove the 3 screws and cooling fan motor.
  1. INSTALL COOLING FAN MOTOR Install the cooling fan motor with the 3 screws. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) Connect the 5 clamps. NOTE: Be careful not to damage the connector.
  2. INSTALL NO. 2 COOLING FAN MOTOR Install the No. 2 cooling fan motor with the 3 screws. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
  3. INSTALL FAN Install the fan with the nut. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf)
  4. INSTALL NO. 2 FAN Install the No. 2 fan with the nut. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf)
  5. INSTALL RADIATOR ASSEMBLY HINT: Refer to «INSTALLATION»(ref-568743-S17243201162013072300000)

Scheme 31

Scheme 31: ILLUSTRATION
Scheme 31: ILLUSTRATION

Scheme 32

Scheme 32: ILLUSTRATION
Scheme 32: ILLUSTRATION

Scheme 33

Scheme 33: ILLUSTRATION
Scheme 33: ILLUSTRATION

Scheme 34

Scheme 34: ILLUSTRATION
Scheme 34: ILLUSTRATION

Scheme 35

Scheme 35: ON-VEHICLE INSPECTION
Scheme 35: ON-VEHICLE INSPECTION

Scheme 36

Scheme 36
Scheme 36
  1. CHECK RESERVE TANK CAP (for Engine) Measure the valve opening pressure. If there are water stains or foreign matter on O-ring 1, clean it with water and finger scouring. Check that O-ring 1 is not deformed, cracked or swollen. Apply engine coolant to O-ring 1 and rubber packing 2 before using a radiator cap tester. When using the cap tester, tilt it upwards 30 degrees or more. Pump the cap tester several times, and check the maximum pressure*1. TEXT IN ILLUSTRATION *1 Radiator Cap Tester *2 Reserve Tank Cap *a 30° or more Pumping speed 1 pump per second HINT: *1: Even if the cap cannot maintain the maximum pressure, it is not a defect. Judgment Criterion Item Specified Condition Standard value (for brand-new cap) 94 to 122 kPa (1.0 to 1.2 kgf/cm 2 , 13.5 to 17 psi) Minimum standard value (for used cap) 79 kPa (0.8 kgf/cm 2 , 11.4 psi) If the maximum pressure is less than the minimum standard value, replace the reserve tank cap.

Scheme 37

Scheme 37: REMOVAL
Scheme 37: REMOVAL

Scheme 38

Scheme 38
Scheme 38

Scheme 39

Scheme 39
Scheme 39

Scheme 40

Scheme 40
Scheme 40

Scheme 41

Scheme 41
Scheme 41

Scheme 42

Scheme 42
Scheme 42

Scheme 43

Scheme 43
Scheme 43

Scheme 44

Scheme 44
Scheme 44

Scheme 45

Scheme 45
Scheme 45

Scheme 46

Scheme 46
Scheme 46

Scheme 47

Scheme 47
Scheme 47

Scheme 48

Scheme 48
Scheme 48
  1. PRECAUTION NOTE: After turning the power 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 notice before proceeding with work. Refer to «PRECAUTION»(ref-568589-S04857946582013072300000) .
  2. REMOVE REAR NO. 2 FLOOR BOARD . Refer to «REMOVAL - Step 1»(ref-568750-S13952416472013072300000)
  3. REMOVE REAR DECK FLOOR BOX . Refer to «REMOVAL - Step 2»(ref-568750-S13952416472013072300000)
  4. REMOVE REAR NO. 3 FLOOR BOARD . Refer to «REMOVAL - Step 3»(ref-568750-S13952416472013072300000)
  5. REMOVE DECK FLOOR BOX RH . Refer to «REMOVAL - Step 4»(ref-568750-S13952416472013072300000)
  6. REMOVE REAR FLOOR BOARD UPPER NO. 3 PLATE . Refer to «REMOVAL - Step 5»(ref-568750-S13952416472013072300000)
  7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-568589-S03492911652013072300000) .
  8. REMOVE NO. 2 CYLINDER HEAD COVER . Refer to «REMOVAL - Step 20»(ref-568735-S42395500822013072300000)
  9. REMOVE INVERTER COVER ASSEMBLY LH (w/ Cover) . Refer to «REMOVAL - Step 5»(ref-568590-S36755435542013072300000)
  10. REMOVE RADIATOR SUPPORT OPENING COVER . Refer to «REMOVAL - Step 1»(ref-568749-S05660375792013072300000)
  11. REMOVE NO. 1 ENGINE UNDER COVER
  12. DRAIN COOLANT (for Engine) See step 1
  13. REMOVE AIR CLEANER CAP SUB-ASSEMBLY . Refer to «REMOVAL - Step 21»(ref-568735-S42395500822013072300000)
  14. REMOVE INLET AIR CLEANER ASSEMBLY . Refer to «REMOVAL - Step 5»(ref-568740-S42718219202013072300000)
  15. REMOVE AIR CLEANER CASE . Refer to «REMOVAL - Step 23»(ref-568735-S42395500822013072300000)
  16. REMOVE FRONT BUMPER ASSEMBLY Refer to «REMOVAL»(ref-568749-S29808970272013072300000)
  17. REMOVE HIGH PITCHED HORN ASSEMBLY . Refer to «REMOVAL - Step 2»(ref-568771-S32343218512013072300000)
  18. REMOVE LOW PITCHED HORN ASSEMBLY . Refer to «REMOVAL - Step 3»(ref-568771-S32343218512013072300000)
  19. REMOVE MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System) . Refer to «REMOVAL - Step 2»(ref-568608-S36267390132013072300000)
  20. REMOVE HOOD LOCK ASSEMBLY (w/o Engine Hood Courtesy Switch) . Refer to «REMOVAL - Step 10»(ref-568772-S20837405882013072300000)
  21. REMOVE HOOD LOCK ASSEMBLY (w/ Engine Hood Courtesy Switch) . Refer to «REMOVAL - Step 11»(ref-568772-S20837405882013072300000)
  22. REMOVE COOL AIR INTAKE DUCT RETAINER SUB-ASSEMBLY . Refer to «REMOVAL - Step 13»(ref-568733-S26046014462013072300000)
  23. REMOVE NO. 1 INVERTER BRACKET . Refer to «REMOVAL - Step 7»(ref-568590-S36755435542013072300000)
  24. REMOVE HOOD LOCK SUPPORT SUB-ASSEMBLY Remove the bolt and No. 2 water by-pass hose from the hood lock support sub-assembly. Remove the 4 bolts and hood lock support sub-assembly.
  25. REMOVE RADIATOR SUPPORT CUSHION Remove the 2 radiator support cushions.
  26. DISCONNECT NO. 1 RADIATOR HOSE Disconnect the No. 1 radiator hose.
  27. DISCONNECT NO. 2 RADIATOR HOSE Disconnect the No. 2 radiator hose.
  28. DISCONNECT NO. 5 INVERTER COOLING HOSE Disconnect the 3 clamps and No. 5 inverter cooling hose from the fan shroud.
  29. DISCONNECT NO. 1 WATER BY-PASS HOSE Disconnect the No. 1 water by-pass hose.
  30. DISCONNECT NO. 3 WATER BY-PASS HOSE Disconnect the 4 clamps and No. 3 water by-pass hose.
  31. REMOVE NO. 2 FAN SHROUD Remove the 2 bolts, 2 claws and No. 2 fan shroud.
  32. REMOVE RADIATOR ASSEMBLY Disconnect the 2 clamps and 2 connectors. Remove the radiator assembly with the fan shroud. NOTE: Do not apply any excessive force to the cooler condenser assembly, radiator assembly (for inverter) or pipe when removing the radiator assembly. Remove the 2 lower radiator supports. Remove the 2 bolts and radiator assembly.
  1. INSTALL RADIATOR ASSEMBLY Install the radiator assembly with the 2 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) Install the 2 lower radiator supports. Install the radiator assembly with the fan shroud. NOTE: Do not apply any excessive force to the cooler condenser assembly, radiator assembly (for inverter) or pipe when installing the radiator assembly. Connect the 2 connectors and 2 clamps.
  2. INSTALL NO. 2 FAN SHROUD Install the No. 2 fan shroud with the 2 bolts and 2 claws. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
  3. CONNECT NO. 3 WATER BY-PASS HOSE Connect the No. 3 water by-pass hose and 4 clamps.
  4. CONNECT NO. 1 WATER BY-PASS HOSE Connect the No. 1 water by-pass hose.
  5. CONNECT NO. 5 INVERTER COOLING HOSE Connect the 3 clamps and No. 5 inverter cooling hose to the fan shroud.
  6. CONNECT NO. 1 RADIATOR HOSE Connect the No. 1 radiator hose.
  7. CONNECT NO. 2 RADIATOR HOSE Connect the No. 2 radiator hose.
  8. INSTALL RADIATOR SUPPORT CUSHION Install the 2 radiator support cushions.
  9. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY Install the hood lock support sub-assembly with the 4 bolts. Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) Install the No. 2 water by-pass hose to the hood lock support sub-assembly with the bolt. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
  10. INSTALL NO. 1 INVERTER BRACKET . Refer to «INSTALLATION - Step 14»(ref-568590-S07777908362013072300000)
  11. INSTALL COOL AIR INTAKE DUCT RETAINER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 11»(ref-568733-S26409310902013072300000)
  12. INSTALL HOOD LOCK ASSEMBLY (w/o Engine Hood Courtesy Switch) . Refer to «INSTALLATION - Step 2»(ref-568772-S26402577092013072300000)
  13. INSTALL HOOD LOCK ASSEMBLY (w/ Engine Hood Courtesy Switch) . Refer to «INSTALLATION - Step 3»(ref-568772-S26402577092013072300000)
  14. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System) . Refer to «INSTALLATION - Step 1»(ref-568608-S24796843702013072300000)
  15. INSTALL HIGH PITCHED HORN ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-568771-S09419336232013072300000)
  16. INSTALL LOW PITCHED HORN ASSEMBLY . Refer to «INSTALLATION - Step 2»(ref-568771-S09419336232013072300000)
  17. INSTALL FRONT BUMPER ASSEMBLY Refer to «INSTALLATION»(ref-568749-S14801862042013072300000)
  18. INSTALL AIR CLEANER CASE . Refer to «INSTALLATION - Step 68»(ref-568735-S28791889062013072300000)
  19. INSTALL INLET AIR CLEANER ASSEMBLY . Refer to «INSTALLATION - Step 4»(ref-568740-S13944941502013072300000)
  20. INSTALL AIR CLEANER CAP SUB-ASSEMBLY . Refer to «INSTALLATION - Step 70»(ref-568735-S28791889062013072300000)
  21. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected. Refer to «INITIALIZATION»(ref-568589-S03492911652013072300000) .
  22. ADD COOLANT (for Engine) See step 2
  23. INSPECT FOR COOLANT LEAK (for Engine) . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-568726-S04853020212013072300000)
  24. INSTALL NO. 1 ENGINE UNDER COVER
  25. INSTALL RADIATOR SUPPORT OPENING COVER . Refer to «INSTALLATION - Step 3»(ref-568749-S42200779382013072300000)
  26. INSTALL INVERTER COVER ASSEMBLY LH (w/ Cover) . Refer to «INSTALLATION - Step 19»(ref-568590-S07777908362013072300000)
  27. INSTALL NO. 2 CYLINDER HEAD COVER . Refer to «INSTALLATION - Step 98»(ref-568735-S28791889062013072300000)
  28. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE . Refer to «INSTALLATION - Step 70»(ref-568750-S15440718192013072300000)
  29. INSTALL DECK FLOOR BOX RH . Refer to «INSTALLATION - Step 71»(ref-568750-S15440718192013072300000)
  30. INSTALL REAR NO. 3 FLOOR BOARD . Refer to «INSTALLATION - Step 72»(ref-568750-S15440718192013072300000)
  31. INSTALL REAR DECK FLOOR BOX . Refer to «INSTALLATION - Step 73»(ref-568750-S15440718192013072300000)
  32. INSTALL REAR NO. 2 FLOOR BOARD . Refer to «INSTALLATION - Step 74»(ref-568750-S15440718192013072300000)
  33. ADJUST MILLIMETER WAVE RADAR SENSOR (w/ Dynamic Radar Cruise Control System) Refer to «ADJUSTMENT»(ref-568608-S33700383542013072300000)

Scheme 49

Scheme 49: ON-VEHICLE INSPECTION
Scheme 49: ON-VEHICLE INSPECTION

Scheme 50

Scheme 50
Scheme 50
  1. INSPECT COOLING FAN RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 3 - 5 Battery voltage is not applied between terminals 1 and 2 10 kohms or higher 3 - 5 Battery voltage is applied between terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the cooling fan relay.
  2. INSPECT NO. 2 COOLING FAN RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 3 - 4 Battery voltage is not applied between terminals 1 and 2 Below 1 ohms 3 - 4 Battery voltage is applied between terminals 1 and 2 10 kohms or higher 3 - 5 Battery voltage is not applied between terminals 1 and 2 10 kohms or higher 3 - 5 Battery voltage is applied between terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the cooling fan relay.
  3. INSPECT NO. 3 COOLING FAN RELAY Measure the resistance according to the value(s) in the table below. Standard Resistance Tester Connection Condition Specified Condition 3 - 5 Battery voltage is not applied between terminals 1 and 2 10 kohms or higher 3 - 5 Battery voltage is applied between terminals 1 and 2 Below 1 ohms If the result is not as specified, replace the cooling fan relay.

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