radiator LEXUS ES300 2005 Service Manual
[x] Cancel search | Manufacturer: LEXUS, Model Year: 2005, Model line: ES300, Model: LEXUS ES300 2005Pages: 969, PDF Size: 24.08 MB
Page 643 of 969
1307Y-01
A86220
(a)
(b)(d)
(d)
(c)
(b)
(b)
(b)
A86221
(a)
(b)
(c)
(c) 13-6
- INTAKEINTAKE AIR CONTROL VALVE ASSY NO.3 (3MZ-FE)
2091 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
INTAKE AIR CONTROL VALVE ASSY NO.3 (3MZ-FE)
REPLACEMENT
1. DISCONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
2. REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5)
3. REMOVE AIR CLEANER INLET ASSY (See page 19-5)
4. REMOVE AIR CLEANER CAP SUB-ASSY
(a) Disconnect the mass air flow meter connector.
(b) Disconnect the 4 vacuum hoses.
(c) Loosen the hose clamp bolt.
(d) Loosen the 2 bolts, then remove the air cleaner cap.
(e) Remove the air cleaner filter element.
5. REMOVE INTAKE AIR CONTROL VALVE ASSY NO.3
(a) Disconnect the VSV connector.
(b) Disconnect the vacuum hose.
(c) Unfasten the 2 claws, then remove the intake air control
valve No. 3.
6. INSTALL INTAKE AIR CONTROL VALVE ASSY NO.3
7. INSTALL AIR CLEANER CAP SUB-ASSY
Torque: 5.0 NVm (51 kgfVcm, 44 in.Vlbf)
8. INSTALL AIR CLEANER INLET ASSY (See page 19-5)
9. CHECK CONNECTION OF VACUUM HOSE (See page 14-29)
10. INSTALL RADIATOR LOWER AIR DEFLECTOR
11. CONNECT ENGINE WIRE NO. 3 (BATTERY NEGATIVE TERMINAL)
Torque: 5.4 NVm (55 kgfVcm, 48 in.Vlbf)
12. SYSTEM INITIALIZATION (See page 19-15)
Page 650 of 969
160QB-01
A60522
Radiator Cap
Tester
- COOLINGCOOLING SYSTEM (3MZ-FE)
16-1
2279 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
COOLING SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
1. INSPECT COOLING SYSTEM FOR LEAKS
(a) Remove the water outlet cap.
CAUTION:
To avoid the danger of being burned, do not remove the wa-
ter outlet cap while the engine and radiator are still hot.
Thermal expansion will cause hot engine coolant and
steam to blow out from the radiator.
(b) Fill the radiator with coolant, then attach a radiator cap
tester.
(c) Warm up the engine.
(d) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), then check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator and water
pump for leaks. If there are no signs or traces of external coolant
leaks, check the heater core, cylinder block and head.
(e) Reinstall the water outlet cap.
2. CHECK ENGINE COOLANT LEVEL AT RESERVOIR
(a) The engine coolant should be between the ºLOWº and ºFULLº lines when the engine is cold.
If low, check for leaks and add ºToyota Super Long Life Coolantº or similar high quality ethylene glycol based
non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology
up to the ºFULLº line.
3. CHECK ENGINE COOLANT QUALITY
(a) Remove the water outlet cap.
CAUTION:
To avoid the danger of being burned, do not remove the water outlet cap while the engine and radiator
are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.
(b) Check if there are any excessive deposits of rust or scale around the water outlet cap and water outlet
filler hole; the coolant should free of oil.
If excessively dirty, replace the coolant.
(c) Reinstall the water outlet cap.
Page 654 of 969
160QC-01
P13560
P00436
A85445
10 mm
(0.39 in.)
- COOLINGCOOLING SYSTEM (3MZ-FE)
16-3
2281 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
INSPECTION
1. INSPECT THERMOSTAT
HINT:
The thermostat is inscribed with the valve opening temperature.
(a) Immerse the thermostat in water, then gradually heat the
water.
(b) Inspect the valve opening temperature of the thermostat.
Valve opening temperature:
80 to 84C (176 to 183F)
If the valve opening temperature is not as specified, replace the
thermostat.
(c) Inspect the valve lift.
Valve lift: 10 mm (0.39 in.) or more at 95C (203F)
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve is fully closed when the thermostat
is at low temperature (below 77C (171F)).
If not fully closed, replace the thermostat.
2. INSPECT WATER OUTLET CAP SUB-ASSY
NOTICE:
If the water outlet cap is contaminated, rinse it with
water.
Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.
When performing the following steps (a) and (b), keep
the tester at an angle of over 30 above horizontal.
Page 655 of 969
A85446
Radiator Cap Tester
30 or more
Water Outlet Cap 16-4
- COOLINGCOOLING SYSTEM (3MZ-FE)
2282 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push / 3 seconds or more
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the water
outlet cap.
(b) Pump the tester, then measure the relief valve opening
pressure.
Pump speed: 1 push within 1 second
NOTICE:
The above pump speed is for the first pump only (in order
to close the vacuum valve). After the first pump, the pump
speed can be reduced.
Standard opening pressure:
83 to 113 kPa (0.85 to 1.15 kgf/cm
2, 12.1 to 16.4 psi)
Minimum opening pressure:
69 kPa (0.7 kgf/cm
2, 10.0 psi)
HINT:
Use the tester's maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the water
outlet cap.
Page 658 of 969
160QF-01
A86582
Drain Cock Plug
Radiator Drain Plug
Drain Cock Plug
Water Outlet Cap
- COOLINGENGINE COOLANT (3MZ-FE)
16-9
2287 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
ENGINE COOLANT (3MZ-FE)
REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the water outlet cap from the water outlet.
CAUTION:
To avoid the danger of being burned, do not remove the wa-
ter outlet cap while the engine and radiator are still hot.
Thermal expansion will cause hot engine coolant and
steam to blow out from the radiator.
(b) Loosen the radiator drain plug and 2 drain cock plugs,
then drain the coolant.
(c) Close the radiator drain plug.
(d) Tighten the 2 drain cock plugs.
Torque: 13 NVm (130 kgfVcm, 9 ftVlbf)
2. ADD ENGINE COOLANT
(a) Slowly fill the cooling system with coolant.
Capacity: 9.2 liters (9.7 US qts, 8.1 lmp. qts)
HINT:
Use of improper coolants may damage the engine cooling system.
Use ºToyota Super Long Life Coolantº or similar high quality ethylene glycol based non-silicate, non-
amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology.
New Toyota vehicles are filled with Toyota Super Long Life Coolant (color is pink, premixed ethylene-
glycol concentration is approximately 50% and freezing temperature is -35C (-31F)). When replac-
ing the coolant, Toyota Super Long Life Coolant is recommended.
Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several
times by hand. If the coolant level goes down, add the coolant.
NOTICE:
Do not use plain water alone.
3. CHECK FOR ENGINE COOLANT LEAKS
(a) Fill the radiator with coolant, then attach a radiator cap tester.
(b) Pump it to 118 kPa (1.2
kgf/cm2
17.1 psi), then check for leakage.
Page 665 of 969
160QI-01
A80823
A80824
A80298
Jiggle Valve15
15 16-16
- COOLINGTHERMOSTAT (3MZ-FE)
2294 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
THERMOSTAT (3MZ-FE)
REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. DRAIN ENGINE COOLANT (See page 16-9)
3. REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5)
4. REMOVE AIR CLEANER INLET ASSY (See page 19-5)
5. REMOVE AIR CLEANER ASSY (See page 19-5)
6. REMOVE WATER INLET PIPE
(a) Remove the bolt and water inlet pipe.
(b) Remove the O-ring from the water inlet pipe.
7. REMOVE WATER INLET
(a) Disconnect the wire harness clamp.
(b) Remove the 3 nuts and water inlet.
8. REMOVE THERMOSTAT
9. INSTALL THERMOSTAT
(a) Install a new gasket to the thermostat.
(b) Align the thermostat jiggle valve with the upper stud bolt,
then insert the thermostat in the water inlet housing.
HINT:
The jiggle valve may be set within 15 of either side of the pre-
scribed position.
10. INSTALL WATER INLET
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)
Page 667 of 969
160QJ-01
A86584: Specified torque Battery Clamp
Sub-assy
Battery
Battery Tray
VSV Connector
Air Cleaner
Inlet Assy
Air Cleaner Inlet
No. 1
Air Cleaner BracketAir Cleaner Case Air Cleaner
Filter Element
Sub-assyAir Cleaner Cap
Sub-assy Mass
Air Flow Sensor
Connector Vacuum Hose
5.0 (51, 44 in.Vlbf)
x2
x2 x3
5.0 (51, 44 in.Vlbf)
5.0 (51, 44 in.Vlbf)
Air Cleaner Hose No. 1
N´m (kgf´cm, ft´lbf)Vacuum Hose
5.0 (51, 44 in.Vlbf)
Radiator Lower Air Deflector
Clip
x7
Clip
Engine Under Cover No. 2
Engine Under Cover No. 1
5.5 (56, 49 in.Vlbf)
7.5 (76, 66 in.Vlbf)
16-18
- COOLINGRADIATOR ASSY (3MZ-FE)
2296 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
RADIATOR ASSY (3MZ-FE)
COMPONENTS
Page 668 of 969
A86585
Hood Lock Release
Lever ProtectorHood Lock Assy
Radiator AssyRadiator Support
Cushion
Radiator Support
LowerRadiator Support Upper
Fan Shroud
Sub-assy
Temperature Detect
Switch
Radiator Hose Outlet
Radiator Hose Inlet
Oil Cooler
Inlet Hose
Oil Cooler
Outlet Hose
5.0 (51, 44 in.Vlbf)
14 (142, 10)
8.0 (82, 71 in.Vlbf)
x3x5
x3
: Specified torque
N´m (kgf´cm, ft´lbf)
- COOLINGRADIATOR ASSY (3MZ-FE)
16-19
2297 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Page 669 of 969
A86586
Radiator Tank Upper
Radiator Tank LowerInlet No. 1
Inlet No. 2 ATM Oil CoolerRadiator Core Sub-assy
Radiator Drain
Cock Plug O-ring
O-ring O-ring
O-ring
O-ring
Washer
Washer
8.3 (85, 74 in.Vlbf)
15 (150, 11)
8.3 (85, 74 in.Vlbf)
15 (150, 11)
N´m (kgf´cm, ft´lbf)
: Specified torque
Non-reusable part 16-20
- COOLINGRADIATOR ASSY (3MZ-FE)
2298 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
Page 670 of 969
160QK-01
A61350
Clip
A86560
A86561
- COOLINGRADIATOR ASSY (3MZ-FE)
16-21
2299 Author: Date:
2005 LEXUS ES330 REPAIR MANUAL (RM1124U)
REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. DRAIN ENGINE COOLANT (See page 16-9)
3. REMOVE ENGINE UNDER COVER NO.1
4. REMOVE ENGINE UNDER COVER NO.2
5. REMOVE RADIATOR LOWER AIR DEFLECTOR (See page 19-5)
6. REMOVE BATTERY
7. REMOVE BATTERY TRAY
8. REMOVE AIR CLEANER INLET ASSY (See page 19-5)
9. REMOVE AIR CLEANER ASSY (See page 19-5)
10. REMOVE AIR CLEANER BRACKET (See page 19-5)
11. REMOVE AIR CLEANER INLET NO.1 (See page 19-5)
12. DISCONNECT RADIATOR HOSE INLET
13. DISCONNECT RADIATOR HOSE OUTLET
14. DISCONNECT OIL COOLER INLET HOSE
15. DISCONNECT OIL COOLER OUTLET HOSE
16. REMOVE HOOD LOCK RELEASE LEVER
PROTECTOR
(a) Using a screwdriver with the tip wrapped in tape, remove
the protector.
NOTICE:
Removing the protector damages the clips inside the pro-
tector, therefore it is necessary to use a new protector
when installing.
17. SEPARATE HOOD LOCK ASSY
(a) Disconnect the hood switch connector.
(b) Remove the 3 bolts, then separate the hood lock.
18. REMOVE RADIATOR SUPPORT UPPER
(a) Disconnect the horn connectors.
(b) Remove the 5 bolts, then remove the radiator support up-
per.