Engine Cooling System (Service Information): Removal & Installation Lexus GX J150

REMOVAL

HINT

If the thermostat is not installed, cooling efficiency decreases. Even if the engine tends to overheat, do not remove the thermostat.

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1. REMOVE UPPER RADIATOR SUPPORT SEAL . Refer to «REMOVAL - Step 14»(ref-524246-S36416482222013012800000)
2. REMOVE LOWER FRONT BUMPER COVER . Refer to «REMOVAL - Step 6»(ref-524246-S36416482222013012800000)
3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY . Refer to «REMOVAL - Step 7»(ref-524246-S36416482222013012800000)
4. DRAIN ENGINE COOLANT See step 5
5. REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to «REMOVAL - Step 15»(ref-524246-S36416482222013012800000)
6. REMOVE AIR CLEANER CAP AND HOSE . Refer to «REMOVAL - Step 23»(ref-524246-S36416482222013012800000)
7. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
8. REMOVE AIR CLEANER CASE SUB-ASSEMBLY . Refer to «REMOVAL - Step 25»(ref-524246-S36416482222013012800000)
9. REMOVE AIR TUBE SUB-ASSEMBLY . Refer to «REMOVAL - Step 12»(ref-524275-S42256539412013012800000)
10. DISCONNECT NO. 2 RADIATOR HOSE See step 12
11. REMOVE WATER INLET SUB-ASSEMBLY WITH THERMOSTAT Remove the 3 nuts, water inlet with thermostat and gasket.

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1. INSPECT WATER INLET SUB-ASSEMBLY WITH THERMOSTAT HINT: The valve opening temperature is stamped on the water inlet with thermostat. Immerse the water inlet with thermostat in water and gradually heat the water. Check the valve opening temperature. Standard valve opening temperature 80 to 84°C (176 to 183°F) If the valve opening temperature is not within the specified range, replace the water inlet sub-assembly with thermostat. Check the valve lift. Standard valve lift 10 mm (0.394 in.) or more at 95°C (203°F) TEXT IN ILLUSTRATION *1 Valve Lift If the valve lift is not as specified, replace the water inlet sub-assembly with thermostat. Check that the valve is fully closed when the water inlet with thermostat is at a low temperature (below 77°C (171°F)). If the valve is not fully closed, replace the water inlet sub-assembly with thermostat.

INSTALLATION

1. INSTALL WATER INLET SUB-ASSEMBLY WITH THERMOSTAT Install a new gasket and the water inlet with thermostat with the 3 nuts. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. CONNECT NO. 2 RADIATOR HOSE See step 6
3. INSTALL AIR TUBE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 10»(ref-524275-S22685514592013012800000)
4. INSTALL AIR CLEANER CASE SUB-ASSEMBLY . Refer to «INSTALLATION - Step 51»(ref-524246-S15625075792013012800000)
5. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
6. INSTALL AIR CLEANER CAP AND HOSE . Refer to «INSTALLATION - Step 53»(ref-524246-S15625075792013012800000)
7. ADD ENGINE COOLANT See step 6
8. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-524249-S11423921442013012800000)
9. INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 80»(ref-524246-S15625075792013012800000)
10. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 88»(ref-524246-S15625075792013012800000)
11. INSTALL LOWER FRONT BUMPER COVER . Refer to «INSTALLATION - Step 89»(ref-524246-S15625075792013012800000)
12. INSTALL UPPER RADIATOR SUPPORT SEAL . Refer to «INSTALLATION - Step 81»(ref-524246-S15625075792013012800000)

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1. CHECK RADIATOR CAP SUB-ASSEMBLY WARNING: Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns. Measure the valve opening pressure. If there are water stains or foreign matter on rubber packing 1, 2 or 3, clean it by using water and finger scouring. Check that rubber packing 1, 2 and 3 are not deformed, cracked or swollen. Check that rubber packing 3 and 4 are not stuck together. Apply engine coolant to rubber packing 2 and 3. When using a radiator cap tester, tilt it more than 30°. TEXT IN ILLUSTRATION *1 Radiator Cap *2 Radiator Cap Tester *a More than 30° Pump the radiator cap tester several times and check the maximum pressure.*1 Pumping speed 1 pump per second HINT: *1: Even if the radiator cap cannot maintain the maximum pressure, it is not necessarily defective. Standard Judgment Criterion Item Specified Condition Standard value (for brand-new cap) 93 to 123 kPa (1.0 to 1.3 kgf/cm 2 , 13.5 to 18 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 radiator cap sub-assembly.
2. INSPECT FINS FOR BLOCKAGE If the fins are clogged, wash them with water or a steam cleaner and dry them with compressed air. NOTE: To avoid damaging the fins, the injection direction should be at right angles to the core surface. If the steam cleaner is too close to the core, there is a possibility of damaging the fins, so maintain the following injection distances. Standard Injection Distance Injection Pressure Specified Condition 2942 to 4903 kPa (30.0 to 50.0 kgf/cm 2 , 427 to 711 psi) 300 mm (11.8 in.) 4903 to 7845 kPa (50.0 to 80.0 kgf/cm 2 , 711 to 1138 psi) 500 mm (19.7 in.) If the fins are bent, straighten them with a screwdriver or pliers. Do not expose electronic components to water. Dry the fins with compressed air.

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1. REMOVE UPPER RADIATOR SUPPORT SEAL . Refer to «REMOVAL - Step 14»(ref-524246-S36416482222013012800000)
2. REMOVE V-BANK COVER SUB-ASSEMBLY . Refer to «REMOVAL - Step 15»(ref-524246-S36416482222013012800000)
3. REMOVE LOWER FRONT BUMPER COVER . Refer to «REMOVAL - Step 6»(ref-524246-S36416482222013012800000)
4. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY . Refer to «REMOVAL - Step 7»(ref-524246-S36416482222013012800000)
5. DRAIN ENGINE COOLANT See step 5
6. REMOVE FRONT BUMPER COVER Remove the front bumper cover. Refer to «REMOVAL»(ref-524282-S34917898992013012800000) .
7. REMOVE RADIATOR SIDE DEFLECTOR LH Using a clip remover, detach the 3 claws and remove the clip. Then move the radiator side deflector so that the radiator can be removed in the step below.
8. REMOVE RADIATOR SIDE DEFLECTOR RH Using a clip remover, detach the 3 claws and remove the clip. Then move the radiator side deflector so that the radiator can be removed in the step below.
9. REMOVE RADIATOR RESERVOIR ASSEMBLY Disconnect the radiator reservoir hose from the radiator. Remove the 3 bolts and radiator reservoir.
10. REMOVE NO. 1 RADIATOR HOSE Remove the No. 1 radiator hose.
11. REMOVE FAN SHROUD Loosen the 4 nuts holding the fluid coupling. Remove the fan and generator V-ribbed belt. Refer to «REMOVAL»(ref-524246-S10356726722013012800000) . Remove the 2 bolts holding the fan shroud. Remove the 4 nuts of the fluid coupling, and then remove the fan shroud together with the fluid coupling. NOTE: Be careful not to damage the radiator core. Remove the fan pulley from the water pump.
12. DISCONNECT NO. 2 RADIATOR HOSE Disconnect the No. 2 radiator hose.
13. DISCONNECT OIL COOLER ACCESSORY ASSEMBLY Disconnect the 2 hoses and oil cooler accessory from the radiator.
14. REMOVE RADIATOR ASSEMBLY Remove the 4 bolts and radiator.
15. REMOVE NO. 2 RADIATOR HOSE Remove the No. 2 radiator hose from the radiator.
16. REMOVE NO. 1 RADIATOR SUPPORT Remove the 2 No. 1 radiator supports from the radiator.
17. REMOVE NO. 2 RADIATOR SUPPORT Remove the 2 No. 2 radiator supports from the radiator.
18. REMOVE NO. 1 RADIATOR SUPPORT BUSH Remove the 4 No. 1 radiator support bushes from the radiator.
19. REMOVE NO. 1 RADIATOR TO SUPPORT SEAL Remove the No. 1 radiator to support seal from the radiator.
20. REMOVE NO. 2 RADIATOR TO SUPPORT SEAL Remove the No. 2 radiator to support seal from the radiator.

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1. INSTALL NO. 2 RADIATOR TO SUPPORT SEAL Install the No. 2 radiator to support seal to the radiator.
2. INSTALL NO. 1 RADIATOR TO SUPPORT SEAL Install the No. 1 radiator to support seal to the radiator.
3. INSTALL NO. 1 RADIATOR SUPPORT BUSH Install the 4 No. 1 radiator support bushes to the radiator.
4. INSTALL NO. 2 RADIATOR SUPPORT Install the 2 No. 2 radiator supports to the radiator.
5. INSTALL NO. 1 RADIATOR SUPPORT Install the 2 No. 1 radiator supports to the radiator.
6. INSTALL NO. 2 RADIATOR HOSE Install the No. 2 radiator hose to the radiator. TEXT IN ILLUSTRATION *1 Paint Mark *a Upper Side *b RH Side HINT: When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.
7. INSTALL RADIATOR ASSEMBLY Insert the 2 tabs of the 2 No. 1 radiator supports into the 2 radiator service holes. Install the radiator with the 4 bolts. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
8. CONNECT OIL COOLER ACCESSORY ASSEMBLY Connect the 2 hoses and oil cooler accessory to the radiator.
9. CONNECT NO. 2 RADIATOR HOSE Connect the No. 2 radiator hose. TEXT IN ILLUSTRATION *1 Paint Mark *a Upper Side *b Rear HINT: When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.
10. INSTALL FAN SHROUD Install the fan pulley to the water pump. Place the fan shroud together with the fluid coupling between the radiator and engine. NOTE: Be careful not to damage the radiator core. Temporarily install the fluid coupling to the water pump with the 4 nuts. Tighten the nuts as much as possible by hand. Set the fan shroud on the radiator as shown in the illustration. Install the shroud with the 2 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Install the fan and generator V-ribbed belt. Refer to «INSTALLATION»(ref-524246-S04919993912013012800000) . Tighten the 4 nuts of the fluid coupling. Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
11. INSTALL NO. 1 RADIATOR HOSE Install the No. 1 radiator hose. TEXT IN ILLUSTRATION *1 Paint Mark *a Upper Side *b Rear *c LH Side HINT: When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.
12. INSTALL RADIATOR RESERVOIR ASSEMBLY Install the radiator reservoir with the 3 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) Connect the radiator reservoir hose to the radiator.
13. INSTALL RADIATOR SIDE DEFLECTOR RH Attach the 3 claws and install the radiator side deflector with the clip.
14. INSTALL RADIATOR SIDE DEFLECTOR LH Attach the 3 claws and install the radiator side deflector with the clip.
15. INSTALL FRONT BUMPER COVER Install the front bumper cover. Refer to «INSTALLATION»(ref-524282-S37345556302013012800000) .
16. ADD ENGINE COOLANT See step 6
17. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-524249-S11423921442013012800000)
18. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 88»(ref-524246-S15625075792013012800000)
19. INSTALL LOWER FRONT BUMPER COVER . Refer to «INSTALLATION - Step 89»(ref-524246-S15625075792013012800000)
20. INSTALL V-BANK COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 80»(ref-524246-S15625075792013012800000)
21. INSTALL UPPER RADIATOR SUPPORT SEAL . Refer to «INSTALLATION - Step 81»(ref-524246-S15625075792013012800000)