cooling LEXUS GS400 2000 Service Owner's Manual

CO0A5±01
P 1111 7
ProtrusionJiggle Valve
± COOLING (2JZ±GE)THERMOSTAT
CO±13
1551 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
INSTALLATION
1. PLACE THERMOSTAT IN WATER INLET
(a) Install a new gasket to the thermostat.
(b) Align the jiggle valve of the thermostat with the protrusion
of the water inlet.
2. INSTALL WATER INLET
Install the water inlet with the 2 nuts.
Torque: 9.0 N´m (90 kgf´cm, 80 in.´lbf)
3. FILL WITH ENGINE COOLANT
4. START ENGINE AND CHECK FOR COOLANT LEAKS

CO0A6±01
CO±14
± COOLING (2JZ±GE)RADIATOR
1552 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
RADIATOR
ON±VEHICLE CLEANING
CLEAN RADIATOR
Using water or a steam cleaner, remove any mud or dirt from the radiator core.
NOTICE:
If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Main-
tain a distance between the cleaner nozzle and radiator core.)

CO0A7±01
CO1242
Radiator Cap Tester
Radiator Cap
30° or More
B01882
Radiator Cap Tester
± COOLING (2JZ±GE)RADIATOR
CO±15
1553 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
ON±VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
Remove the radiator cap from the radiator.
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.
2. INSPECT RADIATOR CAP
NOTICE:

If the radiator cap has contaminations, always rinse
it with water.

Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.

When performing steps (a) and (b) below, keep the
tester at an angle of over 30° above the horizontal.
(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 radiator
cap.
(b) Pump the radiator cap tester, and measure the relief valve
opening pressure.
Pump speed: 1 push within 1 second
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Standard opening pressure:
93 ± 123 kPa (0.95 ± 1.25 kgf/cm
2, 13.5 ± 17.8 psi)
Minimum opening pressure:
78 kPa (0.8 kgf/cm
2, 11.4 psi)
HINT:
Use the tester's maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and head.
4. REINSTALL RADIATOR CAP

CO0A8±01
B02029
Air Cleaner Inlet
Upper Radiator Support
Air Cleaner and MAF
Meter Assembly
Lower Radiator Support
Intake Air Resonator
Engine Under Cover
x 18
ECT Switch
Connector for
Electric Cooling
Fan Lower Radiator Hose
Upper Radiator Support
Upper Radiator Hose
ECM Outlet Duct
Wire Clamp
Electric Cooling
Fan Connector
Oil Cooler Hose
for A/T Engine Wire
Clamp MAF Meter Connector
Radiator and Electric
Cooling Fan Assembly
EVAP Hose
CO±16
± COOLING (2JZ±GE)RADIATOR
1554 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
COMPONENTS

B00917
Radiator Reservoir Hose
Electric Cooling Fan
Assembly
Radiatorx 6
B01859

Packing Upper Tank

O±Ring
Core
Drain Plug

Non±reusable part

Packing

Packing

Packing

Packing

Packing

O±Ring

O±RingPipe
Pipe
Plate Washer Nut
Nut

O±Ring
ECT Switch for Electric
Cooling Fan

O±Ring

O±Ring
Lower Tank
Radiator Cap
Oil Cooler
± COOLING (2JZ±GE)RADIATOR
CO±17
1555 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)

CO0A9±03
B01881
CO±18
± COOLING (2JZ±GE)RADIATOR
1556 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
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 HandlePart A
ClawSST
B01865
Lock
PlateSST
Stopper BoltTank
B01867
Ta p
B02033
± COOLING (2JZ±GE)RADIATOR
CO±19
1557 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
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
HoseConnect
CO±2
± COOLING (2JZ±GE)COOLANT
1540 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
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 ºToyota Long Life Coolantº 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 ºFULLº
line.
3. CHECK ENGINE COOLANT FOR LEAKS
4. CHECK ENGINE COOLANT SPECIFIC GRAVITY COR-
RECTLY

CO0AB±03
B01862
75°
Pipe
CO0317O±Ring Normal X TwistedX Twisted
B01868
CORRECT
WRONG
Ta pTank
Plate
Lock
CO1206
Dimension B
Punch Assembly
Overhaul HandleStopper BoltPartSST
CO±20
± COOLING (2JZ±GE)RADIATOR
1558 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
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.)

B01863B01866B02081
8 7
6 5
43
2
1
Stopper
Bolt
SSTTank
Lock
Plate
B01861(1) (2)(3) (1)
(1)(1)(1) (3)
(3)
(3) (3)
B01864B01870B02082
B01869
H
± COOLING (2JZ±GE)RADIATOR
CO±21
1559 Author: Date:
2000 LEXUS GS300/GS400 (RM718U)
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 ports (1),
flange (2) and bracket (3).

The points shown in the illustration cannot be staked with
the 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): 7.40 ± 7.80 mm (0.2913 ± 0.3071 in.)
If not within the specified height, adjust the stopper bolt of the
handle again and caulk again.
6. INSTALL ECT SWITCH
(a) Install a new O±ring to the ECT switch.
(b) Install the ECT switch.
7. INSTALL DRAIN PLUG
(a) Install a new O±ring to the drain plug.