ES300 1992-1997

Removal & Installation

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Specific to:

Lexus ES300 1992-1996

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Drain the cooling system.

    Click image to see an enlarged view

    Fig. Thermostat and related components

  4.  
  5. Remove the air cleaner cap assembly.
  6.  
  7. Disconnect the heater hose.
  8.  
  9. Remove the bolt and disconnect the hydraulic cooling motor pressure hose from the water inlet.
  10.  
  11. Disconnect the engine wire from the thermostat housing and cylinder head by removing the two nuts.
  12.  
  13. Disconnect the two ECT switch connectors from the thermostat housing.
  14.  
  15. Remove the bolt holding the water inlet pipe to the cylinder head.
  16.  
  17. Disconnect the water inlet pipe from the thermostat housing and remove the O-ring.
  18.  
  19. Remove the three nuts and thermostat housing from the engine.
  20.  
  21. Remove the thermostat and gasket.

    Click image to see an enlarged view

    Fig. Remove the water inlet and thermostat

  22.  

To install:

  1. Clean the gasket mating surfaces.
  2.  
  3. Be sure to use a new thermostat and gasket. Install the thermostat with the spring inside the engine block. Align the jiggle valve on the thermostat with the stud bolt on the thermostat housing. The jiggle valve may be set within 15 degrees of either side of the prescribed position.

    Click image to see an enlarged view

    Fig. Align the jiggle valve of the thermostat with stud bolt (A), and insert the thermostat in the water inlet housing

  4.  
  5. Install the thermostat housing and the three retaining nuts. Torque the nuts to 69 inch lbs. (8 Nm).
  6.  
  7. Using a new O-ring, connect the water inlet pipe to the thermostat housing.
  8.  
  9. Install the bolt holding the water inlet pipe to the cylinder head. Torque the bolt to 14 ft. lbs. (19 Nm).
  10.  
  11. Connect the ECT switch connectors.
  12.  
  13. Connect the engine wire to the thermostat housing and cylinder head with the two nuts.
  14.  
  15. Install the hydraulic cooling motor pressure hose to the water inlet and torque the bolt to 69 inch lbs. (8 Nm).
  16.  
  17. Connect the heater hose.
  18.  
  19. Install the air cleaner cap assembly.
  20.  
  21. Connect all electrical connectors and all hoses.
  22.  
  23. Fill the engine coolant.
  24.  
  25. Connect the negative battery cable to the battery and start the engine.
  26.  
  27. Top off the engine coolant and check for leaks. Make sure the thermostat works properly. Bleed the cooling system.
  28.  

Specific to:

Lexus ES300 1997-1998

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Drain the cooling system.

    Click image to see an enlarged view

    Fig. Thermostat and related components

  4.  
  5. Remove the air cleaner cap assembly.
  6.  
  7. Disconnect the ECT switch connector.
  8.  
  9. Remove the 2 nuts, and disconnect the engine wire protector from the water inlet and right-hand cylinder head.

    Click image to see an enlarged view

    Fig. Disconnect the engine wire protector from the water inlet and cylinder head

  10.  
  11. Remove the bolt, and disconnect the inlet pipe from the water inlet and left-hand cylinder head.

    Click image to see an enlarged view

    Fig. Disconnect the inlet pipe from the water inlet and cylinder head

  12.  
  13. Remove the O-ring from the inlet pipe.
  14.  
  15. Remove the 3 nuts, water inlet and thermostat.
  16.  
  17. Remove the gasket from the thermostat.

    Click image to see an enlarged view

    Fig. Remove the water inlet and thermostat

  18.  

To install:

  1. Place the thermostat in water pump:
    1. Install a new gasket to the thermostat.
    2.  
    3. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing. The jiggle valve may be set within 15 degrees of either side of the prescribed position.

      Click image to see an enlarged view

      Fig. Align the jiggle valve of the thermostat with stud bolt, and insert the thermostat in the water inlet housing

    4.  

  2.  
  3. Install the water inlet and tighten the three nuts to 69 inch lbs. (8 Nm).
  4.  
  5. Install the water inlet pipe:
    1. Install a new O-ring to the water inlet pipe.
    2.  
    3. Apply soapy water to the O-ring.
    4.  
    5. Connect the water inlet pipe to the water inlet.
    6.  
    7. Install the bolt holding the water inlet pipe to the cylinder head and tighten to 14 ft. lbs. (20 Nm).
    8.  

  6.  
  7. Install the engine wire protector.
  8.  
  9. Connect the ECT switch connector.
  10.  
  11. Reinstall the air filter and air cleaner cap assembly.
  12.  
  13. Fill with engine coolant.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the engine and check for leaks.
  18.  
  19. Recheck engine coolant level.
  20.  

 
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