Cooling (Service Information): Removal & Installation Lexus HS I

INSTALLATION

1. INSTALL TEMPERATURE SWITCH Using a 19 mm deep socket wrench, install a new temperature switch. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) NOTE: Do not apply any excessive force to the heater pipe when installing the temperature switch. Connect the temperature switch connector.
2. ADD ENGINE COOLANT (for Engine) See step 3
3. INSPECT FOR COOLANT LEAK (for Engine) . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-398253-S39073368722011051600000)
4. INSTALL NO. 1 ENGINE UNDER COVER
5. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY . Refer to «INSTALLATION - Step 95»(ref-398215-S14438457332011051600000)

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1. REMOVE NO. 1 ENGINE UNDER COVER
2. DRAIN COOLANT (for Engine) See step 2
3. DISCONNECT NO. 2 RADIATOR HOSE . Refer to «REMOVAL - Step 48»(ref-398215-S40139586082011051600000)
4. REMOVE WATER INLET Remove the 2 nuts and the water inlet from the cylinder block.
5. REMOVE THERMOSTAT Remove the gasket from the thermostat.

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1. INSPECT THERMOSTAT The valve opening temperature is inscribed on the thermostat. Immerse the thermostat in water, and then gradually heat the water. Check the valve opening temperature of the thermostat. Standard valve opening temperature 80 to 84°C (176 to 183°F) If the valve opening temperature is not as specified, replace the thermostat. Check the valve lift. Standard 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 it is not fully closed, replace the thermostat.

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1. INSTALL THERMOSTAT Install a new gasket onto the thermostat. Install the thermostat with the jiggle valve facing upward. TEXT IN ILLUSTRATION *1 Jiggle Valve HINT: The jiggle valve may be set to within 10° on either side of the prescribed position.
2. INSTALL WATER INLET Install the water inlet with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
3. CONNECT NO. 2 RADIATOR HOSE . Refer to «INSTALLATION - Step 45»(ref-398215-S14438457332011051600000)
4. ADD COOLANT (for Engine) See step 3
5. INSPECT FOR COOLANT LEAK (for Engine) . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-398253-S39073368722011051600000)
6. INSTALL NO. 1 ENGINE UNDER COVER

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1. REMOVE NO. 1 ENGINE UNDER COVER
2. REMOVE FRONT NO. 3 ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT (for Engine) See step 2
4. REMOVE EXHAUST PIPE GAS CONTROL ACTUATOR NOTE: When removing the exhaust pipe gas control actuator, use caution because coolant may spill out from the exhaust heat recirculation system. Check that the coolant is cool enough. Check that there is clearance between the rod end and the lever. Disconnect the 2 water hoses. Remove the 3 bolts, 3 nuts, gasket and exhaust pipe gas control actuator case. While closing port A, apply compressed air to port B to remove the exhaust pipe gas control actuator shown in the illustration. TEXT IN ILLUSTRATION *1 Exhaust Pipe Gas Control Stopper *2 Exhaust Pipe Gas Control Actuator *3 Port A *4 Port B HINT: Use a piece of cloth to catch the exhaust pipe gas control actuator. Remove the exhaust pipe gas control stopper.

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1. INSTALL EXHAUST PIPE GAS CONTROL ACTUATOR Apply engine coolant to the O-ring. TEXT IN ILLUSTRATION *1 Exhaust Pipe Gas Control Actuator Case *2 Exhaust Pipe Gas Control Stopper *3 Exhaust Pipe Gas Control Actuator *4 O-ring *5 Piston Install the exhaust pipe gas control actuator and exhaust pipe gas control stopper. NOTE: Be sure to install the exhaust pipe gas control stopper in the correct direction. Check that the O-ring is not deformed, cracked or swollen. Be sure to install the exhaust pipe gas control actuator until it touches the exhaust pipe gas control stopper. When installing the exhaust pipe gas control actuator, do not push on the piston. Make sure that the exhaust pipe gas control actuator and the exhaust pipe gas control stopper are free of oil. Install a new gasket and the exhaust pipe gas control actuator case with the 3 bolts and 3 nuts. TEXT IN ILLUSTRATION *1 Gasket *2 Exhaust Pipe Gas Control Actuator *a Protrusion Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) NOTE: Be sure to install a new gasket in the correct direction. Make sure that the exhaust pipe gas control actuator case and the new gasket are free of oil. HINT: Install the gasket so that the protrusion is located as shown in the illustration. Check that there is clearance between the rod end and the lever. Connect the 2 water hoses.
2. ADD ENGINE COOLANT (for Engine) See step 3
3. INSPECT FOR COOLANT LEAK . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-398253-S39073368722011051600000)
4. INSTALL FRONT NO. 3 ENGINE UNDER COVER
5. INSTALL NO. 1 ENGINE UNDER COVER

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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 *1 Component without harness connected (Cooling Fan Motor) Clamp the 400 A probe of an ammeter over the M+ wire of the cooling fan motor. Measure the current while the motor is operating. Standard Current Item Condition Specified Condition Cooling fan motor Battery voltage applied at 20°C (68°F) 7.4 to 10.9 A 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 *1 Component without harness connected (No. 2 Cooling Fan Motor) Clamp the 400 A probe of an ammeter over the M+ 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 Battery voltage applied at 20°C (68°F) 7.4 to 10.9 A If the result is not as specified, replace the No. 2 cooling fan motor.

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1. REMOVE RADIATOR ASSEMBLY HINT: Refer to «REMOVAL»(ref-398217-S15060424332011051600000) .
2. REMOVE COOLING FAN MOTOR INSULATOR Remove the 2 bolts and cooling fan motor insulator.
3. REMOVE FAN Remove the nut and fan.
4. REMOVE NO. 2 FAN Remove the nut and No. 2 fan.
5. REMOVE COOLING FAN MOTOR Disconnect the clamp and cooling fan motor connector. Remove the 3 screws and cooling fan motor.
6. REMOVE NO. 2 COOLING FAN MOTOR Disconnect the clamp and No. 2 cooling fan motor connector. Remove the 3 screws and No. 2 cooling fan motor.

1. 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) Connect the clamp and No. 2 cooling fan motor connector.
2. 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 clamp and cooling fan motor connector.
3. INSTALL NO. 2 FAN Install the No. 2 fan with the nut. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf)
4. INSTALL FAN Install the fan with the nut. Torque: 6.3 N*m (64 kgf*cm, 56 in.*lbf)
5. INSTALL COOLING FAN MOTOR INSULATOR Install the cooling fan motor insulator with the 2 bolts. Torque: 2.6 N*m (26 kgf*cm, 23 in.*lbf)
6. INSTALL RADIATOR ASSEMBLY HINT: Refer to «INSTALLATION»(ref-398217-S27063971362011051600000) .

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1. INSPECT COOLING FAN ECU Put the vehicle in the following conditions: The power switch is off. The coolant temperature is less than 92°C (198°F). The battery voltage is between 9 and 14 V. The A/C switch is off. Clamp the 400 A probe of an ammeter over the M+ wire of each cooling fan motor. Turn the power switch on (IG) and wait for approximately 10 seconds. Check that the fans stop. Start the engine. Check that the fans are stopped with the engine idling. HINT: Make sure that the engine coolant temperature is less than 92°C (198°F). Make sure that the A/C switch is off. Check that the fans operate when the A/C switch is turned on. Standard Current Item Specified Condition Cooling fan motor 7.4 to 10.9 A No. 2 cooling fan motor 7.4 to 10.9 A HINT: The coolant temperature should be less than 92°C (198°F). Check that the fans operate when the engine coolant temperature sensor connector is disconnected. Standard Current Item Specified Condition Cooling fan motor 7.4 to 10.9 A No. 2 cooling fan motor 7.4 to 10.9 A After the engine is warmed up, check that the fans operate as shown in the illustration. HINT: The coolant temperature at which the fans start operating is approximately 94°C (201°F). This system can also be checked using the Techstream. Enter the following menus: Powertrain / Engine and ECT / Data List / Coolant Temp.

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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 upward 30 degrees or more. Pump the cap tester several times, and check the maximum pressure*1. TEXT IN ILLUSTRATION *1 Radiator Cap Tester *2 Radiator Cap 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 (after using 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.

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1. PRECAUTION (w/ Navigation System) NOTE: After the power switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal.
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL . Refer to «REMOVAL - Step 3»(ref-398219-S28362000682011051600000)
3. REMOVE COOL AIR INTAKE DUCT SEAL . Refer to «REMOVAL - Step 28»(ref-398215-S40139586082011051600000)
4. REMOVE NO. 1 ENGINE UNDER COVER
5. DRAIN ENGINE COOLANT (for Engine) See step 2
6. REMOVE FRONT BUMPER ASSEMBLY . Refer to «REMOVAL - Step 3»(ref-398259-S08115739352011051600000)
7. REMOVE LOW PITCHED HORN ASSEMBLY . Refer to «REMOVAL - Step 3»(ref-398262-S37134246502011051600000)
8. REMOVE HIGH PITCHED HORN ASSEMBLY . Refer to «REMOVAL - Step 2»(ref-398262-S37134246502011051600000)
9. REMOVE MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System) . Refer to «REMOVAL - Step 2»(ref-398095-S20749555302011051600000)
10. REMOVE HOOD LOCK ASSEMBLY . Refer to «REMOVAL - Step 3»(ref-398251-S03076199452011051600000)
11. REMOVE RADIATOR GRILLE BRACKET . Refer to «REMOVAL - Step 9»(ref-398224-S24005698652011051600000)
12. REMOVE NO. 5 INVERTER BRACKET . Refer to «REMOVAL - Step 12»(ref-398232-S32095834502011051600000)
13. REMOVE RADIATOR SUPPORT LH Remove the 2 bolts and radiator support LH. Remove the radiator support cushion from the radiator support LH.
14. REMOVE RADIATOR SUPPORT RH Disconnect the No. 2 water by-pass hose clamp from the radiator support RH. Remove the bolt and radiator support RH. Remove the radiator support cushion from the radiator support RH.
15. REMOVE HOOD LOCK SUPPORT SUB-ASSEMBLY Remove the 4 bolts and hood lock support sub-assembly.
16. DISCONNECT NO. 3 RADIATOR HOSE Disconnect the No. 3 radiator hose and No. 4 water by-pass hose.
17. DISCONNECT NO. 2 RADIATOR HOSE Disconnect the No. 2 radiator hose.
18. DISCONNECT NO. 5 INVERTER COOLING HOSE Disconnect the 4 clamps and No. 5 inverter cooling hose from the fan shroud.
19. DISCONNECT NO. 1 WATER BY-PASS HOSE Disconnect the No. 1 water by-pass hose.
20. DISCONNECT NO. 3 WATER BY-PASS HOSE Disconnect the 4 clamps and No. 3 water by-pass hose from the No. 2 fan shroud. Disconnect the No. 3 water by-pass hose.
21. REMOVE NO. 2 FAN SHROUD Remove the 2 bolts, 2 claws and No. 2 fan shroud.
22. REMOVE RADIATOR SIDE DEFLECTOR RH Disconnect the 3 clips and 2 claws, and remove the radiator side deflector RH.
23. REMOVE RADIATOR AND FAN ASSEMBLY Disconnect the 3 wire harness clamps and connector. Remove the radiator assembly from the vehicle together with the cooling fan assembly. NOTE: For vehicles with the air conditioning system, do not apply any excessive force to the cooler condenser assembly or pipe when removing the radiator assembly. Remove the 2 lower radiator supports.
24. REMOVE NO. 1 RADIATOR HOSE Remove the No. 1 radiator hose from the radiator assembly.
25. REMOVE NO. 2 RADIATOR HOSE Remove the No. 2 radiator hose from the radiator assembly.
26. REMOVE RADIATOR ASSEMBLY Remove the 2 bolts and radiator assembly.

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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.
2. INSTALL NO. 2 RADIATOR HOSE Install the No. 2 radiator hose to the radiator assembly.
3. INSTALL NO. 1 RADIATOR HOSE Install the No. 1 radiator hose to the radiator assembly.
4. INSTALL RADIATOR AND FAN ASSEMBLY Install the radiator assembly to the vehicle together with the cooling fan assembly. NOTE: For vehicles with the air conditioning system, do not apply any excessive force to the cooler condenser assembly or pipe when installing the radiator assembly. Connect the 3 wire harness clamps and connector.
5. INSTALL RADIATOR SIDE DEFLECTOR RH Install the radiator side deflector RH with the 3 clips and 2 claws.
6. 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)
7. CONNECT NO. 3 WATER BY-PASS HOSE Connect the No. 3 water by-pass hose. Connect the 4 clamps and No. 3 water by-pass hose to the No. 2 fan shroud.
8. CONNECT NO. 1 WATER BY-PASS HOSE Connect the No. 1 water by-pass hose.
9. CONNECT NO. 5 INVERTER COOLING HOSE Connect the 4 clamps and No. 5 inverter cooling hose to the fan shroud.
10. CONNECT NO. 2 RADIATOR HOSE Connect the No. 2 radiator hose.
11. CONNECT NO. 3 RADIATOR HOSE Connect the No. 3 radiator hose and No. 4 water by-pass hose.
12. INSTALL HOOD LOCK SUPPORT SUB-ASSEMBLY Install the hood lock support sub- assembly with the 4 bolts. Torque: 13 N*m (128 kgf*cm, 9 ft.*lbf)
13. INSTALL RADIATOR SUPPORT RH Install the radiator support cushion to the radiator support RH. Install the bolt and radiator support RH. Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) Connect the No. 2 water by-pass hose clamp to the radiator support RH.
14. INSTALL RADIATOR SUPPORT LH Install the radiator support cushion to the radiator support LH. Install radiator support LH with the 2 bolts. Bolt A Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) Bolt B Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
15. INSTALL NO. 5 INVERTER BRACKET . Refer to «REMOVAL - Step 12»(ref-398232-S32095834502011051600000)
16. INSTALL RADIATOR GRILLE BRACKET . Refer to «INSTALLATION - Step 11»(ref-398224-S03267570642011051600000)
17. INSTALL HOOD LOCK ASSEMBLY See step 12
18. INSTALL MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System) . Refer to «INSTALLATION - Step 1»(ref-398095-S06940428802011051600000)
19. INSTALL HIGH PITCHED HORN ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-398262-S29373299932011051600000)
20. INSTALL LOW PITCHED HORN ASSEMBLY . Refer to «INSTALLATION - Step 2»(ref-398262-S29373299932011051600000)
21. INSTALL FRONT BUMPER ASSEMBLY . Refer to «INSTALLATION - Step 1»(ref-398259-S22402231542011051600000)
22. ADD ENGINE COOLANT (for Engine) See step 3
23. INSPECT FOR COOLANT LEAK (for Engine) . Refer to «ON-VEHICLE INSPECTION - Step 1»(ref-398253-S39073368722011051600000)
24. INSTALL NO. 1 ENGINE UNDER COVER
25. INSTALL COOL AIR INTAKE DUCT SEAL . Refer to «INSTALLATION - Step 96»(ref-398215-S14438457332011051600000)
26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL . Refer to «INSTALLATION - Step 2»(ref-398219-S33566720602011051600000)
27. ADD WASHER FLUID (w/ Headlight Cleaner System) . Refer to «INSTALLATION - Step 2»(ref-398237-S13510395882011051600000)
28. ADJUST FOG LIGHT AIMING HINT: Refer to «ADJUSTMENT»(ref-398250-S15603411282011051600000) .

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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.