Canada - Cooling System - Coolant Residue OnWater Outlet
Bulletin2392
Issue Date
April 24, 2007
Title
COOLANT RESIDUE ON WATER OUTLET SUB-ASSEMBLY
Component
ENGINE
Models
'06 IS250
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 IS 250 vehicles produced BEFORE the Production Change Effective VINs shown below.
PRODUCTION CHANGE INFORMATION:
WARRANTY INFORMATION:
PARTS INFORMATION:
REQUIRED TOOLS & MATERIAL:
REQUIRED SSTS:
REPAIR PROCEDURE:
1. Remove the cool air intake duct seal by removing the 11 clips.
2. Remove the V-bank cover sub-assembly.
A. Raise the V-bank cover to disengage the clip on the rear of the cover.
B. Raise the cover again to disengage the 2 clips on the front of the cover and remove the cover.
NOTE:
Attempting to disengage both front and rear clips at the same time may cause the cover to break.
3. Remove the No. 1 inlet air cleaner by removing the bolt and clip.
4. Inspect cooling system components for leaks and/or coolant residue accumulation.
Refer to the Repair Manual within E-TAS / TIS library:
- Division: Lexus
- Model: IS 250
- Year: 2006
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: 4GR-FSE Cooling: Cooling System: On-Vehicle Inspection
5. 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 and reservoir tank 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.
6. Remove the No. 2 engine cover by removing the 3 clips and clamp.
7. Remove the water outlet 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.
8. If leakage is confirmed in step 4, remove and replace the radiator assembly.
Refer to the Repair Manual within E-TAS / TIS library:
- Division: Lexus
- Model: IS 250
- Year: 2006
- Service Category: Engine/Hybrid System
- Section: Cooling
- Keyword: 4GR-FSE Cooling: Radiator: Installation
- Keyword: 4 GR-FSE Cooling: Radiator: Removal
1. Install the water outlet sub-assembly.
A. Install a new water inlet housing gasket No.1 and water outlet pipe O-ring.
B. 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)
C. Install the water outlet sub-assembly 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.
D. Connect the 5 hoses.
2. Install the No. 2 engine cover.
A. Install the No. 2 engine cover with the 3 clips.
B. Connect the clamp.
3. If leakage was confirmed in step 4 of the Removal procedure, replace the inlet and/or outlet radiator hose(s) and radiator hose clamps.
4. Connect the radiator hoses. Connect the radiator inlet hose and radiator outlet hose to the radiator assembly and secure them with the clips.
HINT:
- Make sure that the claws on the clips are positioned as shown in the illustration.
- Dimension "a" in the illustration (between the hose end and the clip end) should be less than 1.0 - 5.0 mm (0.04 - 0.20 in.)
- Connect the hoses until they make contact with each stopper. (Dimension "b" should be less than 2.5 mm [0.10 in.]).
5. Install the No. 1 inlet air cleaner with the bolt and clip.
Torque: 5 N-m (51 kgf-cm, 44 ft-lbf)
6. 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.
7. Check for engine coolant leakage.
8. Install the V-bank cover sub-assembly. Engage the 2 clips on the front of the cover, and then engage the clip on the rear to install the V-bank cover.
NOTE:
Be sure to engage the clips securely.
Do NOT apply excessive force or hit the cover to engage the clips. This may cause the cover to break.
9. Install the cool air intake duct seal.
10. 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.