Canada - Cooling System - Coolant Residue On Water Outlet
Bulletin2393
Issue Date
April 24, 2007
Title
COOLANT RESIDUE ON WATER OUTLET SUB-ASSEMBLY
Component
ENGINE
Models
'06 GS300
INTRODUCTION:
Some customers may complain of an accumulation of coolant residue on the water outlet sub-assembly, radiator, and/or radiator hoses. The water outlet sub-assembly has been improved to correct this condition. Follow the repair procedure below to replace the water outlet sub-assembly along with the radiator and/or radiator hoses if coolant residue is present.
APPLICABLE VEHICLES:
- 2006 model year GS300 vehicles produced BEFORE the Production Change Effective VINs shown below.
PRODUCTION CHANGE INFORMATION:
WARRANTY INFORMATION:
PARTS INFORMATION:
REQUIRED TOOLS & MATERIAL:
REQUIRED SSTS:
REPAIR PROCEDURE REMOVAL:
1. Remove the engine under cover.
A. Using a clip remover, remove the 3 clips.
B. Remove the 10 screws and under cover.
2. Remove the cool air intake duct seal.
Using a clip remover, remove the 7 clips and duct seal.
3. Remove the No. 1 air cleaner inlet by removing the bolt and inlet.
4. Remove the V-bank cover sub-assembly by removing the 2 nuts and cover.
5. Inspect cooling system components for leaks and/or coolant residue accumulation.
Refer to the Repair Manual within E-TAS / TIS library:
- Division: Lexus
- Model: GS300
- Year: 2006
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: 3GR-FSE Cooling: Cooling System: On-Vehicle Inspection
6. Drain the engine coolant.
CAUTION:
Do NOT remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
A. Remove the radiator cap, vent plug and reservoir cap.
B. Loosen the radiator drain cock plug and 2 cylinder block drain cock plugs. Then drain the coolant.
HINT: Collect the coolant in a container and dispose of it according to the regulations in your area.
7. Remove the No. 2 engine cover by removing the 3 nuts.
8. Remove the water outlet sub-assembly.
A. Disconnect the 2 radiator hoses.
B. Disconnect the 5 hoses.
C. Remove the 4 bolts, nut, and water outlet sub-assembly.
D. Remove the water inlet sub-assembly with thermostat. Remove the 3 nuts, water inlet with thermostat, and gasket.
E. Remove the water inlet housing gasket and water outlet pipe's O-ring.
9. If leakage is confirmed in step 5, remove and replace the radiator assembly.
Refer to the Repair Manual within E-TAS / TIS library:
- Division: Lexus
- Model: GS300
- Year: 2006
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: 3GR-FSE Cooling: Radiator: Installation
- Keyword: 3GR-FSE Cooling: Radiator: Removal
REPAIR PROCEDURE: INSTALLATION
1. Install the water outlet sub-assembly.
A. Install a new gasket to the water inlet housing.
B. Install a new O-ring to the water outlet pipe.
C. Install the water inlet sub-assembly with thermostat. Install a new gasket and the water inlet with thermostat with the 3 nuts.
Torque: 10 N-m (102 kgf-cm, 7 ft-lbf)
D. Install the water outlet with the 4 bolts and nut.
Torque: 10 N-m (102 kgf-cm, 7 ft-lbf)
NOTE:
Be careful not to allow the O-ring to get caught between parts.
E. Connect the 5 hoses.
2. If leakage was confirmed in step 5 of the Removal procedure, replace the inlet and/or outlet radiator hose(s) and radiator hose clamps.
3. Connect the 2 radiator hoses.
4. Add engine coolant.
A. Tighten all the plugs and fill the radiator with Super Long Life Coolant (SLLC).
Torque: 12.7 N-m (130 kgf-cm, 9 ft-lbf)
B. Add engine coolant. Specified capacity: 9.6 US qts (9.1 liters, 8.0 Imp. qts)
C. Slowly pour coolant into the radiator reservoir until it reaches the FULL line.
D. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant. If the coolant level is low, add coolant.
E. Install the radiator cap and reservoir cap.
F. Bleed air from the cooling system.
a. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
b. Maintain the engine speed at 2,000 to 2,500 rpm.
c. Press the inlet and outlet radiator hoses several times by hand to bleed air.
G. Stop the engine, and wait until the engine coolant cools down to ambient temperature.
H. Check the coolant level in the radiator reservoir. If the coolant level is low, add SLLC to the radiator reservoir FULL line.
5. Check for engine coolant leaks.
6. Install remaining parts in reverse order of removal.
7. Confirm that the repair corrected the condition.
NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.