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Contents Wiring diagrams Section: Cooling System (Mechanical) All sections

Cooling Lexus ES XV30

Cooling System (Mechanical) 17 illustrations ~2022 words

Scheme 1

Scheme 1: ON-VEHICLE INSPECTION
Scheme 1: ON-VEHICLE INSPECTION
  1. Inspect cooling system for leaks. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. Fill the radiator with coolant and attach a radiator cap tester. Warm up the engine. Pump it to 118 kPa (1.2 kgf/cm 2 , 17.1 psi), and check that the pressure does not drop. If the pressure drops, check to hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.
  2. Check engine coolant level at reservoir. The engine coolant level should be between the "LOW" and "FULL" lines, when the engine is cold. If low, check for leaks and add "Toyota Long Life Coolant" or equivalent up to the "FULL" line.
  3. Check engine coolant quality. Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. Check if there is any excessive deposits of rust or scale around the radiator cap and radiator filler hole; the coolant should be free from oil. NOTE: If excessively dirty, replace the coolant. Reinstall the radiator cap.

Scheme 2

Scheme 2: INSPECTION
Scheme 2: INSPECTION

Scheme 3

Scheme 3
Scheme 3

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5
  1. Thermostat. NOTE: The thermostat is numbered with the valve opening temperature. Immerse the thermostat in water and gradually heat the water. Check the valve opening temperature. Valve opening temperature : 80-84°C(176-183°F) If the valve opening temperature is not as specified, replace the thermostat. Check the valve lift. Valve lift : 10 mm (0.394 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the thermostat. Check that the valve is fully closed when the thermostat is at low temperatures (below 77°C (171 °F)). If not closed, replace the thermostat.
  2. Water outlet cap sub-assembly. NOTE: If the reservoir cap has contaminations, always rinse it with water. Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water. When performing steps (a) and (b) below, keep the tester at an angle of over 30° above the horizontal. Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve. Pump speed : One push/3 seconds or more NOTE: Push the pump at a constant speed. If air is not coming from the vacuum valve, replace the reservoir cap. Pump the tester and measure the relief valve opening pressure. Pump speed : One push within one second NOTE: This pump speed is for the first pump only (in order to close the vacuum valve). After this, the pump speed can be reduced. Standard opening pressure : 83.4-112.8 kPa (0.85-1.15 kgf/cm 2 , 12.1-16.4 psi) Minimum opening pressure : 69 kPa (0.7 kgf/cm 2 , 10.0 psi) NOTE: Use the tester's maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the reservoir cap.

ON-VEHICLE INSPECTION

Note. It is normal that the cooling fan sometime rotates when the ignition switch is turned from ACC to ON.

  1. Check cooling fan operation with low temperature (Below 83°C (181 °F)). Turn the ignition switch ON. Check that the cooling fan stops. If not, check the cooling fan relay and water temperature switches, and check for disconnection of connectors or wire break between the cooling fan relay and water temperature switches. Disconnect the water temperature switch No. 1 connector. Connect terminals on the water temperature switch No. 1 connector. Check that the No. 1 cooling fan rotates at high speed. If not, check the No. 1 cooling fan relay and No. 1 cooling fan. Reconnect the water temperature switch No. 1 connector. Disconnect the water temperature switch No. 2 connector. Ground terminal on the water temperature switch No. 2 wire harness side connector. Check that the No. 1 and No. 2 cooling fans rotate at low speed. If not, check the No. 2 cooling fan relay, No. 3 cooling fan relay and No. 2 cooling fan. Reconnect the water temperature switch No. 2 connector
  2. Inspect cooling fan. Disconnect the cooling fan connector. Connect battery and ammeter to the cooling fan connector. Check that the cooling fan rotates smoothly, and check the reading on the ammeter. Standard amperage : 8.0-12.0 A at 20°C (68°F) Reconnect the cooling fan connector.

Scheme 6

Scheme 6: INSPECTION
Scheme 6: INSPECTION

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9
  1. Cooling fan relay. Cooling fan relay No. 3 Inspect the cooling fan relay continuity. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. Apply battery voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay.
  2. Cooling fan relay No. 2 Inspect the cooling fan relay continuity. Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the relay. Using an ohmmeter, check that there is continuity between terminals 3 and 4. If there is no continuity, replace the relay. Check that there is no continuity between terminals 3 and 5. If there is continuity, replace the relay. Apply battery voltage across terminals 1 and 2. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If there is no continuity, replace the relay.
  3. Temperature detect switch. Using an ohmmeter, check that there is continuity between the terminals when the coolant temperature is above 98°C (208°F). If there is no continuity, replace the switch. Check that there is no continuity, between terminals when the coolant temperature is below 88°C (190°F). If there is continuity, replace the switch.
  4. Temperature detect switch No. 2. Using an ohmmeter, check that there is continuity between the terminals when the coolant temperature is above 93°C (199°F). If there is no continuity, replace the switch. Check that there is no continuity, between terminals when the coolant temperature is below 83°C (181°F). If there is continuity, replace the switch.

Scheme 10

Scheme 10: REPLACEMENT
Scheme 10: REPLACEMENT
  1. Drain coolant. Remove the radiator cap from the water outlet. CAUTION: To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. Loosen the radiator drain plug and drain the coolant.
  2. Add coolant. Slowly fill the system with coolant. NOTE: Use of improper coolants may damage engine cooling system. Use "Toyota Long Life Coolant" or equivalent and mix it with plain water according to the manufacturer's directions. Using of coolant with includes more than 50% (freezing protection down to -35°C (-31°F) or 60% (freezing protection down to -50°C (-58°F)) of ethylene-glycol is recommended but not more than 70%. NOTE: Do not use an alcohol type coolant or plain water alone. The coolant should be mixed with plain water (preferably demineralized water). Capacity: 9.2 liters (9.7 US qts, 8.1 lmp. qts)
  3. Check engine coolant leak. Fill the radiator with coolant and attach a radiator cap tester. Pump it to 118 kPa (1.2 kgf/cm 2 ), and check leakage.

Scheme 11

Scheme 11: REPLACEMENT
Scheme 11: REPLACEMENT

Scheme 12

Scheme 12
Scheme 12
  1. Drain coolant. See step 1 under COOLANT.
  2. Remove front wheel RH.
  3. Remove front fender apron seal RH.
  4. Remove V belt No. 1 (cooler compressor to crankshaft pulley)
  5. Remove vane pump V belt.
  6. Remove Engine Moving Control Rod. See step 2, under «REMOVAL»(ref-159137-S27481671682003111300000) .
  7. Remove engine mounting stay No. 2 RH. See step 2 under «REMOVAL»(ref-159137-S27481671682003111300000) .
  8. Remove generator bracket No. 2
  9. Remove crankshaft pulley. See «TIMING BELT REPLACEMENT»(ref-156551) . SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05030)
  10. Remove timing belt No. 1 cover.
  11. Remove timing belt No. 2 cover. See «TIMING BELT REPLACEMENT»(ref-156551) .
  12. Remove transverse engine mounting bracket.
  13. Remove timing belt guide No. 2.
  14. Remove timing belt. See «REPLACEMENT»(/lexus/es/xv30-2001-2003/remont/lubrication-system/#lubrication) .
  15. Remove timing belt idler sub-assembly No. 2. Remove the bolt and timing belt idler sub-assembly No. 2.
  16. Remove camshaft timing pulley. See «CAMSHAFT»(ref-159137-S20806121372003111300000) . SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
  17. Remove timing belt No. 3 cover
  18. Remove water pump assembly. Remove the 4 bolts, 2 nuts and water pump assembly.
  19. Install water pump assembly. Install a new gasket and the water pump with the 4 bolts and 2 nuts. Torque: 8 N.m (82 kgf.cm, 71 in.lbf)
  20. Install timing belt No. 3 cover. See «REMOVAL (ES 300)»(ref-156551-S32111464412003072200000) .
  21. Install camshaft timing pulley. See «CAMSHAFT»(ref-159137-S20806121372003111300000) . SST 09962-01000, 09963-01000, 09960-10010, 09249-63010
  22. Install timing belt idler sub-assembly No. 2. Torque: 43 N.m (438 kgf.cm, 32 ft.lbf)
  23. Inspect timing belt. See «TIMING BELT REPLACEMENT»(ref-156551) .
  24. Install timing belt. See «TIMING BELT REPLACEMENT»(ref-156551) . SST 09960-10010 (09962-01000, 09963-01000)
  25. Install chain tensioner assembly No. 1. See «TIMING BELT REPLACEMENT»(ref-156551) .
  26. Install timing belt guide No. 2. See «TIMING BELT REPLACEMENT»(ref-156551) .
  27. Install transverse engine mounting bracket. Torque : 28 N.m (286 kgf.cm, 21 ft.lbf)
  28. Install timing belt No. 2 cover. See «TIMING BELT REPLACEMENT»(ref-156551) .
  29. Install timing belt No. 1 cover. See «TIMING BELT REPLACEMENT»(ref-156551) .
  30. Install crankshaft pulley. See «TIMING BELT REPLACEMENT»(ref-156551) . SST 09213-54015 (91651-60855), 09330-00021
  31. Install generator bracket No. 2. Torque: 28 N.m (286 kgf.cm, 21 ft.lbf)
  32. Install engine mounting stay No. 2 RH. See step 2 under «REMOVAL»(ref-159137-S27481671682003111300000) .
  33. Install engine moving control rod. See step 2 under «REMOVAL»(ref-159137-S27481671682003111300000) .
  34. Install vane pump V belt.
  35. Install V (cooler compressor to crankshaft pulley) belt No. 1
  36. Inspect drive belt deflection and tension (reference). See «ENGINE MECHANICAL»(ref-159137) .
  37. Add coolant. See step 2 under COOLANT.
  38. Check engine coolant leak. See step 3 under COOLANT.
  39. Install front wheel RH. Torque: 103 N.m (1051 kgf.cm, 76 ft.lbf)

Scheme 13

Scheme 13: INSPECTION
Scheme 13: INSPECTION
  1. Inspect water pump assembly. Visually check the drain hole for coolant leakage. Turn the pulley, and check that the water pump bearing moves smoothly and quietly.

Scheme 14

Scheme 14: REPLACEMENT
Scheme 14: REPLACEMENT
  1. Drain coolant. See step 1 under COOLANT.
  2. Remove battery.
  3. Remove air cleaner inlet assembly.
  4. Remove air cleaner assembly with hose.
  5. Remove air cleaner bracket.
  6. Remove air cleaner inlet No. 1.
  7. Disconnect radiator hose outlet.
  8. Remove water inlet pipe. Remove the bolt and water inlet pipe.
  9. Remove water inlet. Remove the 3 bolts and water inlet.
  10. Remove thermostat.
  11. Install thermostat. Install a new gasket to the thermostat. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing. NOTE: The jiggle valve may be set within 15° of either side of the prescribed position.
  12. Install water inlet. Torque: 8 N.m (82 kgf.cm, 71 in.lbf)
  13. Install water inlet pipe. Install a new O-ring to the water inlet pipe. Apply soapy water to the O-ring. Connect the water inlet pipe to the water inlet. Install the bolt holding the water inlet pipe to the cylinder head. Torque: 20 N.m (204 kgf.cm, 15 ft.lbf)
  14. Install air cleaner assembly with hose.
  15. Connect vacuum hose.
  16. Add coolant. See step 2 under COOLANT.
  17. Check engine coolant leak. See step 3 under COOLANT.

Scheme 15

Scheme 15: REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY
Scheme 15: REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17
  1. Drain coolant. See step 1 under COOLANT.
  2. Disconnect radiator hose inlet.
  3. Disconnect radiator hose outlet.
  4. Disconnect oil cooler inlet hose.
  5. Disconnect oil cooler outlet hose No. 2.
  6. Remove air cleaner inlet assembly. Remove the 3 bolts, the air cleaner inlet and air cleaner inlet No. 1.
  7. Remove radiator support upper. Remove the radiator lower air deflector. See COMPONENTS under FRONT BUMPER Disconnect the 2 horn connector. Remove the hood lock release lever cover. Remove the bolt shown in the illustration. Remove the 4 bolts and radiator support upper.
  8. Remove radiator assembly. Disconnect the fan motor connector. Remove the radiator w/fan.
  9. Remove radiator support cushion.
  10. Remove radiator support lower.
  11. Remove fan assembly w/motor.
  12. Install fan assembly w/motor. Install the fan assembly w/motor to the radiator. Torque: 5.0 N.m (51 kgf.cm, 44 in.lbf)
  13. Install radiator support upper. Install the radiator support upper with the 4 bolts. Torque: 14 N.m (142 kgf.cm, 10 ft.lbf)
  14. Adjust hood sub-assembly. See COMPONENTS under FRONT BUMPER.
  15. Add coolant. See step 2 under COOLANT.
  16. Check engine coolant leak. See step 3 under COOLANT.

See also:
• REPLACEMENT