Cooling: Removal & Installation Lexus RX II facelift

INSTALLATION

1. INSTALL WATER PUMP ASSEMBLY Install a new gasket and the water pump with the 3 bolts and 3 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
2. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.1 Using a socket hexagon wrench 10, install the plate washer and timing belt idler No.1 with the pivot bolt. Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) see scheme 15: Locating Water Pump Assembly Bolts And Nuts
3. INSTALL TIMING BELT NO.3 COVER (See INSTALLATION )
4. INSTALL CAMSHAFT TIMING PULLEY (See INSTALLATION )
5. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2 Install the timing belt idler sub-assembly No.2 with the bolt. Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
6. INSPECT TIMING BELT (See INSTALLATION )
7. INSTALL TIMING BELT (See INSTALLATION )
8. INSTALL CHAIN TENSIONER ASSEMBLY NO.1 (See INSTALLATION )
9. INSTALL TIMING BELT GUIDE NO.2 (See INSTALLATION )
10. INSTALL ENGINE MOUNTING BRACKET RH (See INSTALLATION )
11. INSTALL TIMING BELT NO.2 COVER (See INSTALLATION )
12. INSTALL TIMING BELT NO.1 COVER (See INSTALLATION )
13. INSTALL CRANKSHAFT PULLEY (See INSTALLATION )
14. INSTALL ENGINE MOUNTING STAY NO.2 RH (See INSTALLATION )
15. INSTALL ENGINE MOVING CONTROL ROD (See INSTALLATION )
16. INSTALL AIR CLEANER BRACKET (See INSTALLATION )
17. INSTALL RESERVOIR BRACKET (See INSTALLATION )
18. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (See INSTALLATION )
19. INSTALL AIR CLEANER W/RESONATOR (See REMOVAL )
20. INSTALL AIR CLEANER CAP W/INLET (See INSTALLATION )
21. INSTALL COOL AIR INTAKE DUCT SEAL (See INSTALLATION )
22. INSTALL BATTERY CARRIER SUB-ASSEMBLY (See INSTALLATION )
23. INSTALL BATTERY (See INSTALLATION )
24. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER (See INSTALLATION )
25. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See INSTALLATION )
26. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
27. INSTALL FRONT WIPER ARM & BLADE ASSEMBLY RH (See INSTALLATION )
28. INSTALL FRONT WIPER ARM & BLADE ASSEMBLY LH (See INSTALLATION )
29. INSTALL FRONT FENDER APRON SEAL RH (See INSTALLATION )
30. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See INSTALLATION )
31. INSTALL FRONT WHEEL RH
32. ADD COOLANT (for Engine) (See COOLANT (FOR ENGINE) )
33. INSPECT FOR COOLANT LEAK (for Engine) (See COOLING SYSTEM )
34. INSPECT IGNITION TIMING (See ENGINE )
35. PERFORM INITIALIZATION (See INSTALLATION )
36. INSTALL ENGINE ROOM COVER SIDE (See INSTALLATION )
37. INSTALL ENGINE ROOM SIDE LH COVER NO.2 (See INSTALLATION )
38. INSTALL ENGINE UNDER COVER NO.1

Scheme 13

1. WATER PUMP ASSEMBLY Visually check the drain hole for coolant leakage. Turn the pulley and check that the water pump bearing moves smoothly and does not make any noise. see scheme 17: Inspecting Water Pump Assembly

Identifying Wiper Assembly Components With Torque Specification. Scheme 14

Identifying Air Cleaner Assembly Components With Torque Specification. Scheme 15

Identifying Engine Assembly Components With Torque Specification (2WD). Scheme 16

Identifying Engine Assembly Components With Torque Specification (4WD). Scheme 17

Identifying Thermostat Components With Torque Specification. Scheme 18

Scheme 19

1. PRECAUTION (See REMOVAL )
2. REMOVE ENGINE ROOM SIDE LH COVER NO.2 (See REMOVAL )
3. REMOVE ENGINE ROOM COVER SIDE (See REMOVAL )
4. DRAIN COOLANT (for Inverter) (See COOLANT (for Inverter) )
5. DRAIN COOLANT (for Engine) (See COOLANT (FOR ENGINE) )
6. DISCONNECT BATTERY NEGATIVE CABLE
7. REMOVE SERVICE PLUG GRIP (See REMOVAL )
8. REMOVE FRONT WIPER AND BLADE ASSEMBLY ARM RH (See REMOVAL )
9. REMOVE FRONT WIPER AND BLADE ASSEMBLY ARM LH (See REMOVAL )
10. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (See REMOVAL )
11. REMOVE WINDSHIELD WIPER MOTOR ASSEMBLY (See REMOVAL )
12. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER (See REMOVAL )
13. REMOVE COOL AIR INTAKE DUCT SEAL (See REMOVAL )
14. REMOVE AIR CLEANER CAP W/INLET (See REMOVAL )
15. REMOVE AIR CLEANER W/RESONATOR (See REMOVAL )
16. REMOVE POWER STEERING ECU ASSEMBLY (See REMOVAL )
17. DISCONNECT CIRCUIT BREAKER SENSOR NO.1 (See REMOVAL )
18. DISCONNECT ENGINE ROOM WIRE NO.2 (See REMOVAL )
19. REMOVE INVERTER RESERVE TANK SUB-ASSEMBLY (See REMOVAL )
20. DISCONNECT WATER HOSE (See REMOVAL )
21. DISCONNECT POWER STEERING ECU BRACKET (See REMOVAL )
22. REMOVE INVERTER COVER (See REMOVAL )
23. VERIFY VOLTAGE OF W/CONVERTER INVERTER ASSEMBLY IS 0 V (See REMOVAL )
24. SEPARATE ENGINE WIRE NO.4 (See REMOVAL )
25. DISCONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR (See REMOVAL )
26. DISCONNECT MG ECU CONNECTOR (See REMOVAL )
27. DISCONNECT NO.3 WIRE FRAME (See REMOVAL )
28. INSTALL INVERTER COVER (See REMOVAL )
29. SEPARATE ENGINE ROOM RELAY BLOCK ASSEMBLY (See REMOVAL )
30. REMOVE INVERTER BRACKET NO.4 (See INSTALLATION )
31. REMOVE W/CONVERTER INVERTER ASSEMBLY (See INSTALLATION )
32. REMOVE WATER INLET PIPE Remove the bolt and the water inlet pipe. Remove the O-ring from the water inlet pipe. (Scheme 19): Locating Water Inlet Pipe Bolt
33. REMOVE WATER INLET Disconnect the wire harness clamp. Remove the 3 nuts and the water inlet.
34. REMOVE THERMOSTAT Remove the thermostat. Remove the gasket from the thermostat. (Scheme 20): Locating Water Inlet Nuts

Scheme 20

1. INSTALL THERMOSTAT Install a new gasket to the thermostat. Align the jiggle valve of the thermostat and water inlet, and insert the thermostat in the water inlet housing. HINT: The jiggle valve should be set within +- 15° from the prescribed position. see scheme 25: Identifying Jiggle Valve Position
2. INSTALL WATER INLET Install the 3 nuts and the water inlet with the 3 nuts. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) see scheme 26: Locating Water Inlet Nuts
3. 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 which is used to fix the water inlet pipe to the cylinder head with the bolt. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) (Scheme 21): Locating Water Inlet Pipe Bolt
4. INSTALL W/CONVERTER INVERTER ASSEMBLY (See INSTALLATION )
5. INSTALL INVERTER BRACKET NO.4 (See INSTALLATION )
6. INSTALL ENGINE ROOM RELAY BLOCK ASSEMBLY (See INSTALLATION )
7. REMOVE INVERTER COVER (See INSTALLATION )
8. CONNECT NO.3 WIRE FRAME (See INSTALLATION )
9. CONNECT MG ECU CONNECTOR (See INSTALLATION )
10. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR (See INSTALLATION )
11. CONNECT ENGINE WIRE NO.4 (See INSTALLATION )
12. CHECK HIGH VOLTAGE CABLE CONNECTION (See INSTALLATION )
13. INSTALL INVERTER COVER (See INSTALLATION )
14. INSTALL POWER STEERING ECU BRACKET (See INSTALLATION )
15. CONNECT WATER HOSE (See INSTALLATION )
16. INSTALL INVERTER RESERVE TANK SUB-ASSEMBLY (See INSTALLATION )
17. CONNECT ENGINE ROOM WIRE NO.2 (See INSTALLATION )
18. CONNECT CIRCUIT BREAKER SENSOR NO.1 (See INSTALLATION )
19. INSTALL POWER STEERING ECU ASSEMBLY (See INSTALLATION )
20. INSTALL INVERTER BRACKET NO. 5 (See INSTALLATION )
21. INSTALL AIR CLEANER W/RESONATOR (See INSTALLATION )
22. INSTALL AIR CLEANER CAP W/INLET (See INSTALLATION )
23. INSTALL COOL AIR INTAKE DUCT SEAL (See INSTALLATION )
24. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER (See INSTALLATION )
25. INSTALL WINDSHIELD WIPER LINK ASSEMBLY (See INSTALLATION )
26. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
27. INSTALL FRONT WIPER AND BLADE ASSEMBLY ARM LH (See INSTALLATION )
28. INSTALL FRONT WIPER AND BLADE ASSEMBLY ARM RH (See INSTALLATION )
29. INSTALL SERVICE PLUG GRIP (See INSTALLATION )
30. REMOVE ENGINE ROOM COVER SIDE (See INSTALLATION )
31. INSTALL ENGINE ROOM SIDE LH COVER NO.2 (See INSTALLATION )
32. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
33. ADD COOLANT (for Inverter) (See REPLACEMENT )
34. ADD COOLANT (for Engine) (See COOLANT (FOR ENGINE) )
35. INSPECT FOR COOLANT LEAK (for Inverter)
36. INSPECT FOR COOLANT LEAK (for Engine) (See COOLING SYSTEM )
37. PERFORM INITIALIZATION (See INSTALLATION )

Scheme 21

Scheme 22

Scheme 23

1. INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. (Scheme 22): Identifying Valve Opening Temperature On Thermostat Immerse the thermostat in water and gradually heat the water. Check the valve opening temperature of the thermostat. Valve opening temperature: 80 to 84°C (176 to 183°F) HINT: If the valve opening temperature is not as specified, replace the thermostat. (Scheme 23): Checking Valve Opening Temperature Of Thermostat Check the valve lift. Valve lift: 10 mm (0.394 in.) or more at 95°C (203°F) HINT: If the valve lift is not as specified, replace the thermostat. (Scheme 24): Identifying Valve Lift Check that the valve is fully closed when the thermostat temperature is low (below 77°C (171°F)). HINT: If not closed, replace the thermostat.

Scheme 24

Scheme 25

1. CHECK NO. 1 COOLING FAN MOTOR Check that the motor turns smoothly when the battery is connected to the fan motor connector. Measure the current while the motor is turning. Standard current: 9 to 25 A at 20°C (68°F) If the result is not as specified, replace the No.1 cooling fan motor. (Scheme 25): Identifying Cooling Fan Motor Connector Terminals
2. CHECK NO. 2 COOLING FAN MOTOR Check that the motor turns smoothly when the battery is connected to the fan motor connector. Measure the current while the motor is turning. Standard current: 9 to 25 A at 20°C (68°F) If the result is not as specified, replace the No.2 cooling fan motor. (Scheme 26): Identifying Cooling Fan Motor Connector Terminals

Scheme 26

Scheme 27

Scheme 28

1. CHECK COOLING FAN ECU (NO.1 and NO.2) Inspect the input voltage. Disconnect the cooling fan ECU connectors. Turn the ignition switch on. Measure the voltage between terminals +B and GND. (Scheme 27): Identifying Cooling Fan ECU Connector Terminals Standard voltage: 8 to 15 V If the voltage is not as specified, check the fusible links, fuses, wire harness and fan relay. Reconnect the connectors. HINT: Wire harness condition is diagnosed by cooling fan operation. COOLING FAN OPERATION AND WIRE HARNESS CONDITION REFERENCE Cooling fan operation Wire harness condition Not in operation Short In continuous operation Open Check the HV control ECU power source. Check RFC1 and RFC2 signal generation. NOTE: Perform this inspection when engine coolant temperature is 82°C (180°F) Connect an oscilloscope to terminals RFC1 (RFC2) and E1 of the HV control ECU. (Scheme 28): Identifying HV Control ECU Connector Terminals Check the signal generation and measure the current according to the value(s) in the table below. (Scheme 29): Waveform Graph CURRENT SPECIFICATION Condition RFC1 (RFC2) signal generation Fan operation Fan operation Engine stopped, IG switch ON - - Not operate Engine idling, A/C ON - - Not operate Engine idling, A/C ON See Diagram 1 3 to 13 A Operate Engine idling, engine coolant temperature sensor connector disconnected See Diagram 2 3 to 21 A Operate (High speed) HINT: If RFC1 (RFC2) signal is not as specified, replace the HV control ECU. When the fan amperage has a problem even if the RFC1 (RFC2) signal that has no problem, replace the cooling fan ECU.

Scheme 29

1. CHECK COOLING FAN RELAY NO.1 Remove the relay from the fusible link block. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition 3 - 5 10 Mohms or higher 3 - 5 Below 1 ohms (when battery voltage is applied to terminals 1 and 2) see scheme 36: Identifying Cooling Fan Relay Connector Terminals If the result is not as specified, replace the cooling fan relay NO.1. Install the relay to the engine room No.1 relay block.
2. CHECK COOLING FAN RELAY NO.2 Remove the relay from the fusible link block. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition 3 - 5 10 Mohms or higher 3-5 Below 1 Q (when battery voltage is applied to terminals 1 and 2) see scheme 37: Identifying Cooling Fan Relay Connector Terminals If the result is not as specified, replace the cooling fan relay NO.2. Install the relay to the fusible link block.

Identifying Radiator Components With Torque Specification (1 Of 2). Scheme 30

Identifying Radiator Components With Torque Specification (2 Of 2). Scheme 31

Scheme 32

1. INSPECT RADIATOR CAP SUB-ASSEMBLY If there are water stains or foreign matter on portion 1,2 or 3, clean the part(s) by: 1) washing with water, and 2) rubbing with your hand(s), a nylon brush, or equivalent. Check that portion 1, 2 or 3 is not deformed or swollen. Check that portions 3 and 4 are not stuck together. (Scheme 32): Identifying Radiator Cap Sub-Assembly Apply coolant to portions 2 and 3 before using the radiator cap tester. HINT: When using the radiator cap tester, tilt the radiator cap upward 30° or more as shown in the illustration. Pump the tester several times and read the maximum pressure. (*1) Pumping speed: One pumping maximum per second (*1): Even if the maximum pressure is not maintained, the radiator cap sub-assembly can be considered normal. (Scheme 33): Inspecting Radiator Cap Sub-Assembly Standard OPENING VALVE PRESSURE SPECIFICATION Opening valve pressure 88 kPa (0.9 kgf/cm 2 ) Standard: 74.0 to 103.0 kPa (0.75 to 1.05 kgf/cm 2 ) If the opening valve pressure is not within the standard range, replace the radiator cap.

Scheme 33

1. CHECK FINS BLOCKAGE Check that the radiator and condenser are not blocked with leaves, dirt, or insects. Clean the hose connections. If the fins are blocked, wash them with water or a steam cleaner. CAUTION: If the distance between the steam cleaner and core is too close, the fins may be damaged. Keep the following injection distance. (Scheme 34): Identifying Fins INJECTION DISTANCE AND INJECTION PRESSURE SPECIFICATION Injection Distance Injection Pressure 300 mm (11.81 in.) 2,942 to 4,903 kPa (30 to 50 kgf*cm 2, 427 to 711 psi) 500 mm (19.69 in.) 4,903 to 7,845 kPa (50 to 80 kgf*cm 2, 711 to 1,138 psi) If the fins are bent, straighten them with a screwdriver or pliers. Never apply water directly onto the electric components. Dry the fins with compressed air.

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

1. DRAIN COOLANT (for Engine) (See COOLANT (FOR ENGINE) )
2. REMOVE ENGINE UNDER COVER NO.1
3. REMOVE COOL AIR INTAKE DUCT SEAL (See REMOVAL )
4. REMOVE AIR CLEANER CAP W/INLET (See REMOVAL )
5. DISCONNECT RADIATOR HOSE INLET Disconnect the radiator hose inlet from the No.2 radiator assembly. (Scheme 35): Locating Radiator Hose Inlet
6. DISCONNECT RADIATOR HOSE OUTLET Disconnect the radiator hose outlet from the No.2 radiator assembly. (Scheme 36): Locating Radiator Hose Outlet
7. SEPARATE HOOD LOCK ASSEMBLY Remove the 2 screws. Detach the claws and remove the hood lock control cable cover. Using a screwdriver, remove the cap. (Scheme 37): Identifying Hood Lock Assembly Remove the 2 bolts and nut, and separate the hood lock. (Scheme 38): Identifying Hood Lock Assembly Bolts And Nut
8. REMOVE RADIATOR SUPPORT SUB-ASSEMBLY UPPER Remove the bolt and separate the suction tube bracket. Disconnect the horn connectors. Remove the 5 bolts and the radiator support upper. (Scheme 39): Locating Radiator Support Bolts (Upper)
9. REMOVE FAN SHROUD Disconnect the coolant reservoir hose. Disconnect the cooling fan ECU connectors. (Scheme 40): Locating Coolant Reservoir Hose Remove the 4 bolts and the fan shroud. (Scheme 41): Identifying Fan Shroud
10. REMOVE RADIATOR SUPPORT CUSHION Remove the 2 radiator support cushions from the radiator supports. (Scheme 42): Locating Radiator Support Cushions
11. REMOVE RADIATOR SUPPORT SUB-ASSEMBLY LH Remove the 3 bolts and the radiator support LH. (Scheme 43): Locating Radiator Support Bolts (LH)
12. REMOVE RADIATOR SUPPORT SUB-ASSEMBLY RH Remove the 3 bolts and the radiator support RH. (Scheme 44): Locating Radiator Support Bolts (RH)
13. REMOVE NO.2 RADIATOR ASSEMBLY Remove the 4 bolts, and remove the radiator from the radiator support lowers. (Scheme 45): Locating Radiator Bolts (LH) (Scheme 46): Locating Radiator Bolts (RH) Lift the radiator, then remove it. NOTE: Do not allow the cooler condenser and radiator to come into contact with each other. (Scheme 47): Removing Radiator

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. INSTALL NO.2 RADIATOR ASSEMBLY Attach the radiator from the upper part. NOTE: Do not allow the cooler condenser and radiator to come into contact with each other. (Scheme 48): Installing Radiator Install the radiator and radiator support lowers with the 4 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) see scheme 57: Locating Radiator Bolts (LH) (Scheme 49): Locating Radiator Bolts (RH)
2. REMOVE RADIATOR SUPPORT SUB-ASSEMBLY LH Install the radiator support LH with the 3 bolts. Torque: Bolt A 5.0 N*m (51 kgf*cm, 44 in.*lbf) Bolt B 3.9 N*m (40 kgf*cm, 35 in.*lbf) (Scheme 50): Locating Radiator Support Bolts (LH)
3. INSTALL RADIATOR SUPPORT SUB-ASSEMBLY RH Install the 3 bolts and radiator support RH with the 3 bolts. Torque: Bolt A 5.0 N*m (51 kgf*cm, 44 in.*lbf) Bolt B 3.9 N*m (40 kgf*cm, 35 in.*lbf) see scheme 60: Locating Radiator Support Bolts (RH)
4. INSTALL RADIATOR SUPPORT CUSHION Install the 2 radiator support cushions to the radiator supports. see scheme 61: Locating Radiator Support Cushions
5. INSTALL FAN SHROUD Install the 4 bolts and fan shroud to the radiator with the 4 bolts. Torque: 7.8 N*m (80 kgf*cm, 69 ft.*lbf) see scheme 62: Identifying Fan Shroud Install the radiator reserve tank hose. (Scheme 51): Locating Radiator Reserve Tank Hose
6. INSTALL RADIATOR SUPPORT SUB-ASSEMBLY UPPER Install the radiator support upper with the 5 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) NOTE: Secure the upper member with the retaining claws of the radiator upper support. see scheme 64: Locating Radiator Support Bolts (Upper) Connect the horn connector. Install the suction tube bracket with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
7. INSTALL HOOD LOCK ASSEMBLY Install the hood lock assembly with the 2 bolts and nut. Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) see scheme 65: Identifying Hood Lock Assembly Bolts And Nut Attach the claws and install the hood lock control cable cover. Install the 2 screws. see scheme 66: Identifying Hood Lock Assembly
8. INSTALL RADIATOR HOSE INLET Install the radiator hose inlet to the No.2 radiator assembly. see scheme 67: Locating Radiator Hose Inlet
9. INSTALL RADIATOR HOSE OUTLET Install the radiator hose outlet to the No.2 radiator assembly.
10. INSTALL AIR CLEANER CAP W/INLET (See INSTALLATION )
11. INSTALL COOL AIR INTAKE DUCT SEAL (See INSTALLATION ) see scheme 68: Locating Radiator Hose Outlet
12. ADJUST HOOD LOCK ASSEMBLY (See ADJUSTMENT )
13. ADD COOLANT (for Engine) (See COOLANT (FOR ENGINE) )
14. INSPECT FOR COOLANT LEAK (for Engine) (See COOLING SYSTEM )