Lexus GS300/400 (2000 year). Service manual — part 119

CO0A9–03

B01881

CO–18

–

COOLING (2JZ–GE)

RADIATOR

1556

REMOVAL

1.

REMOVE ENGINE UNDER COVER

2.

DRAIN ENGINE COOLANT

3.

REMOVE AIR CLEANER INLET

4.

REMOVE AIR CLEANER AND MAF METER AS-
SEMBLY

5.

REMOVE RADIATOR AND ELECTRIC COOLING FAN
ASSEMBLY

(a)

Disconnect the upper radiator hose from the radiator.

(b)

Disconnect the lower radiator hose from the radiator.

(c)

Disconnect the ECM outlet duct from the ECM box.

(d)

Disconnect the wire for electric cooling fan from the clamp
on the electric cooling fan.

(e)

Disconnect the 2 electric cooling fan connectors.

(f)

Disconnect the ECT switch connector for electric cooling
fan.

(g)

Disconnect the 2 oil cooler hoses for A/T from the radiator.

(h)

Remove the 2 nuts and 2 upper radiator supports.

(i)

Lift out the radiator and cooling fan assembly.

(j)

Remove the 2 lower radiator supports.

6.

REMOVE ELECTRIC COOLING FAN FROM RADIA-
TOR

(a)

Disconnect the radiator reservoir hose from the radiator.

(b)

Remove the 6 bolts and electric cooling fan.

CO0AA–01

CO1205

Dimension B

Stopper Bolt

Overhaul Handle

Part A

Claw

SST

B01865

Lock

Plate

SST

Stopper Bolt

Tank

B01867

Tap

B02033

–

COOLING (2JZ–GE)

RADIATOR

CO–19

1557

DISASSEMBLY

1.

REMOVE PACKINGS

2.

REMOVE RADIATOR CAP

3.

REMOVE DRAIN PLUG

(a)

Remove the drain plug.

(b)

Remove the O–ring.

4.

REMOVE ECT SWITCH

(a)

Remove the ECT switch.

(b)

Remove the O–ring.

5.

ASSEMBLE SST
SST

09230–01010

(a)

Install the claw to the overhaul handle, inserting it in the
hole in part A as shown in the diagram.

(b)

While gripping the handle, adjust the stopper bolt so that
dimension B is as shown in the illustration.
Dimension B: 0.2 – 0.3 mm (0.008 – 0.012 in.)

NOTICE:
If this adjustment is not done the claw may be damaged.

6.

UNCAULK LOCK PLATES

Using SST to release the caulking, squeeze the handle until
stopped by the stopper bolt.

SST

09230–01010

7.

REMOVE TANKS AND O–RINGS

Lightly tap the bracket of the radiator (or radiator inlet or outlet)
with a soft–faced hammer, and remove the tank and the O–ring.

8.

REMOVE OIL COOLER FROM LOWER TANK

(a)

Loosen the nut, and remove the cooler pipe. Remove the
2 cooler pipes.

(b)

Remove the 2 nuts and 2 plate washers.

(c)

Remove the oil cooler and 2 O–rings.

CO09X–03

Z07402

Drain Plug

Drain Plug

B01611

Drain Plug

Rubber
Hose

Connect

CO–2

–

COOLING (2JZ–GE)

COOLANT

1540

REPLACEMENT

1.

DRAIN ENGINE COOLANT

(a)

Remove the radiator cap.

CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(b)

Loosen the 2 drain plugs (for the engine and radiator),
and drain the coolant.

HINT:
To prevent the coolant from spraying over the cylinder block,
connect the rubber hose (inside diameter 6 – 8 mm) in the mar-
ket to the union pipe under the drain plug.
(c)

Close the drain plugs.
Torque: 30 N·m (300 kgf·cm, 22 ft·lbf) for engine

2.

FILL ENGINE COOLANT

(a)

Slowly fill the system with coolant.

Use of improper coolants may damage engine cool-
ing system.

Use ”Toyota Long Life Coolant” or equivalent and
mix it with plain water according to the manufac-
ture’s directions.

Use of the coolant which includes more than 50%
[freezing protection down to –35

°

C (–31

°

F)] or 60%

[freezing protection down to –50

°

C (–58

°

F)] of eth-

ylene –glycol is recommended, but not more than
70%.

NOTICE:

Do not use an alcohol type coolant or plain water
alone.

The coolant should be mixed with plain water (prefer-
able demineralized water or distilled water).
Capacity (w/ Heater):
7.7 liters (8.1 US qts, 6.8 lmp. qts)

(b)

Install the radiator cap.

(c)

Start the engine, and bleed the cooling system.

(d)

Refill the reservoir with coolant until it reaches the ”FULL”
line.

3.

CHECK ENGINE COOLANT FOR LEAKS

4.

CHECK ENGINE COOLANT SPECIFIC GRAVITY COR-
RECTLY

CO0AB–03

B01862

75

°

Pipe

CO0317

O–Ring

Normal X Twisted

X Twisted

B01868

CORRECT

WRONG

Tap

Tank

Plate

Lock

CO1206

Dimension B

Punch Assembly

Overhaul Handle

Stopper Bolt

Part

SST

CO–20

–

COOLING (2JZ–GE)

RADIATOR

1558

REASSEMBLY

1.

INSTALL OIL COOLER TO LOWER TANK

(a)

Install 2 new O–rings to the oil cooler.

(b)

Install the oil cooler to the lower tank with the 2 plate
washers and 2 nuts.
Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf)

(c)

Install the cooler pipes in the direction indicated in the il-
lustration.
Torque: 14.7 N·m (150 kgf·cm, 11 ft·lbf)

2.

INSPECT 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.

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 a 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 is as shown in the illustration.
Dimension B: 8.4 mm (0.331 in.)