Lexus ES300 (1997 year). Service manual — part 302

CO02Z–01

S04435

(1)

(2)

(3)

(4)

(5)

(6)

CO1267

Lock Plate

Core

Lock Plate

CO0317

Normal X Twisted

O–ring

X Twisted

S04736

Tap

CORRECT

WRONG

Tank

Lock
Plate

CO1206

Dimension ”B”

Stopper Bolt

Punch Assembly

Overhaul Handle

Part ”A”

SST

CO–20

–

COOLING

RADIATOR

937

1997 LEXUS ES300 (RM511U)

REASSEMBLY

1.

INSTALL OIL COOLER TO LOWER TANK

(a)

Clean the O–ring contact surface of the lower tank and oil
cooler.

(b)

Install a new O–rings (1) to the oil cooler (2).

(c)

Install the oil cooler with the O–rings to the lower tank (3).

(d)

Install the plate washers (4), and nuts (5). Torque the
nuts.
Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf)

(e)

Install the pipe (6).
Torque: 14.7 N·m (150 kgf·cm, 11 ft·lbf)

2.

INSPECT LOCK PLATE

Inspect the lock plate for damage.
HINT:

If the sides of the lock plate groove are deformed, reas-
sembly of the tank will be impossible.

Therefore, first correct any deformation with pliers or simi-
lar object. Water leakage will result if the bottom of the
lock plate groove is damaged or dented, Therefore, repair
or replace if necessary.

NOTICE:
The radiator can only be recaulked 2 times. After the 2nd
time, the radiator core must be replaced.
3.

INSTALL NEW O–RINGS AND TANKS

(a)

After checking that there are no foreign objects in the lock
plate groove, install the new O–ring without twisting it.

HINT:
When cleaning the lock plate groove, lightly rub it with sand pa-
per without scratching it.

(b)

Install the tank without damaging the O–ring.

(c)

Tap the lock plate with a soft–faced hammer so that there
is no gap between it and the tank.

4.

ASSEMBLE SST
SST

09230–01010, 09231–14010

(a)

Install the punch assembly to the overhaul handle, insert-
ing it in the hole in part ”A” as shown in the illustration.

(b)

While gripping the handle, adjust the stopper bolt so that
dimension ”B” shown in the diagram.
Dimension ”B”: 8.4 mm (0.34 in.)

S04739

1

SST

Stopper
Bolt

2

3

7

5

4

8

6

Tank

Lock
Plate

S04734

Rib

Bracket

S04726

S04735

H

–

COOLING

RADIATOR

CO–21

938

1997 LEXUS ES300 (RM511U)

5.

CAULK LOCK PLATE

(a)

Lightly press SST against the lock plate in the order
shown in the illustration. After repeating this a few times,
fully caulk the lock plate by squeezing the handle until
stopped by the stopper plate.
SST

09230–01010

HINT:

Do not stake the areas protruding around the pipes,
brackets or tank ribs.

The points shown in the rib sides and oil cooler near here
cannot be staked with SST. Use pliers or similar object
and be careful not to damage the core plates.

(b)

Check the lock plate height (H) after completing the caulk-
ing.
Plate height (H): 7.4 – 7.8 mm (0.2959 – 0.3119 in.)

If not within the specified height, adjust the stopper bolt of the
handle again and caulk again.
6.

INSTALL CUSHION

CO030–01

CO–22

–

COOLING

RADIATOR

939

1997 LEXUS ES300 (RM511U)

INSTALLATION

Installation is in the reverse order of removal (See page

CO–17

).

S04724

S04727

Disconnect

CO031–01

S04723

P19531

98

°

C

S04731

Ammeter

Battery

–

COOLING

ELECTRIC COOLING FAN

CO–23

940

1997 LEXUS ES300 (RM511U)

ELECTRIC COOLING FAN

ON–VEHICLE INSPECTION

1.

CHECK COOLING FAN OPERATION WITH LOW
TEMPERATURE (Below 88

°

C (190

°

F))

(a)

Turn the ignition switch ON.

(b)

Check that the cooling fan stops.

If not, check the cooling fan relay and ECT switch, and check
for a separated connector or severed wire between the cooling
fan relay and ECT switch.
(c)

Disconnect the No.1 ECT switch connector.

(d)

Check that the cooling fan rotates.

If not, check the fuses, engine main relay, cooling fan relay,
cooling fan, and check for a short circuit between the cooling
fan relay and ECT switch.
(e)

Reconnect the No.1 ECT switch connector.

2.

CHECK COOLING FAN OPERATION WITH HIGH
TEMPERATURE (Above 98

°

C (208

°

F))

(a)

Start the engine, and raise coolant temperature to above
98

°

C (208

°

F).

(b)

Check that the cooling fan rotates.

If not, replace the No.1 ECT switch.

3.

INSPECT NO.1 COOLING FAN

(a)

Disconnect the cooling fan connector.

(b)

Connect battery and ammeter to the cooling fan connec-
tor.

(c)

Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage: 8.3 – 11.3 A at 20

°

C (68

°

F)

(d)

Reconnect the cooling fan connector.