Lexus GS, SC 1998-06

Removal & Installation

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Click image to see an enlarged view

Fig. Exploded view of the radiator assembly and related components.-2000-05 GS 300, GS 400, and 2001-05 GS 430

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any work.
  4.  
  5. Remove engine under cover.
  6.  
  7. Drain engine coolant.
  8.  
  9. Remove the air cleaner inlet.
  10.  
  11. Remove the air cleaner and Mass Airflow (MAF) meter assembly (if equipped).
  12.  
  13. Remove the radiator and electric cooling fan assembly as follows:


    1. Disconnect the upper radiator hose from the radiator.
    2.  
    3. Disconnect the lower radiator hose from the radiator.
    4.  
    5. Disconnect the ECM outlet duct from the ECM box.
    6.  
    7. For 2001-05 GS 430, disconnect the cooling fan computer connecter.
    8.  
    9. Disconnect the wire for electric cooling fan from the clamp on the electric cooling fan (except 2001-05 GS 430).
    10.  
    11. Disconnect the 2 electric cooling fan connectors (except 2001-05 GS 430).
    12.  
    13. Disconnect the ECT switch connector for electric cooling fan (except 2001-05 GS 430).
    14.  
    15. Disconnect the 2 oil cooler hoses for A/T from the radiator.
    16.  
    17. Remove the 2 nuts and 2 upper radiator supports.
    18.  
    19. Lift out the radiator and cooling fan assembly.
    20.  
    21. Remove the 2 lower radiator supports.
    22.  

  14.  
  15. Remove the electric cooling fan from radiator as follows:


    1. Disconnect the radiator reservoir hose from the radiator.
    2.  
    3. Remove the 6 bolts and electric cooling fan.
    4.  

  16.  

To install:

  1. Install the electric cooling fan to the radiator as follows:


    1. Install the electric cooling fan with the 6 bolts and tighten to 44 inch lbs. (5 Nm).
    2.  
    3. Connect the radiator reservoir hose to the radiator.
    4.  

  2.  
  3. Install the radiator and electric cooling fan assembly as follows:


    1. Install the 2 lower radiator supports to the radiator.
    2.  
    3. Attach the 2 lower radiator supports on the radiator to the body bracket.
    4.  
    5. Install the radiator and electric cooling fan assembly with the 2 upper radiator supports and 2 nuts. Tighten the nuts to 10 ft. lbs. (13.5 Nm).
    6.  
    7. Connect the upper radiator hose to the radiator.
    8.  
    9. Connect the lower radiator hose to the radiator.
    10.  
    11. Connect the ECM outlet duct to the ECM box.
    12.  
    13. Connect the wire for electric cooling fan to the clamp on the electric cooling fan (except 2001-05 GS 430).
    14.  
    15. Connect the 2 electric cooling fan connectors (except 2001-05 GS 430).
    16.  
    17. Connect the ECT switch connector for electric cooling fan (except 2001-05 GS 430).
    18.  
    19. For 2001-05 GS 430, connect the cooling fan computer connecter.
    20.  
    21. Connect the 2 oil cooler hoses for A/T to the radiator.
    22.  

  4.  
  5. Install the air cleaner and MAF meter assembly (if equipped).
  6.  
  7. Install the air cleaner inlet.
  8.  
  9. Refill the engine cooling system.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the engine and check system for coolant leaks and A/T fluid leaks.
  14.  
  15. Install engine under cover.
  16.  



Click image to see an enlarged view

Fig. Front bumper assembly and related components.-2006 GS 300



Click image to see an enlarged view

Fig. Exploded view of the radiator assembly and related components.-2006 GS 300

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any work.
  4.  
  5. Remove the engine under cover.
  6.  
  7. Drain engine coolant.
  8.  
  9. Remove the 2 nuts and V-bank cover.
  10.  
  11. Using a clip remover, remove the 7 clips and cool air intake duct seal.
  12.  
  13. Remove the left and right engine room side covers.
  14.  
  15. Remove the bolt and No. 1 air cleaner inlet.
  16.  
  17. Remove the air cleaner cap with air cleaner hose.
  18.  
  19. Remove the front bumper cover as follows:


    1. Using a clip remover, remove the 2 clips. Put protective tape under the front fender.
    2.  
    3. Remove the 6 screws and 5 bolts.
    4.  
    5. Pull the bumper cover to detach the 3 claws on the LH side.
    6.  
    7. Pull the bumper cover to detach the 3 claws on the RH side and remove the bumper cover.
    8.  
    9. With clearance sonar system: Disconnect the ultrasonic sensor connector.
    10.  

  20.  
  21. Remove the 4 clips and the radiator support opening cover.
  22.  
  23. Remove the hood lock control cable cover.
  24.  
  25. Remove the hood lock assembly.
  26.  
  27. Remove the upper radiator support sub-assembly.
  28.  
  29. Disconnect the hose from the water inlet with thermostat and radiator tank upper.
  30.  
  31. Disconnect the hose from the water inlet and radiator tank lower.
  32.  
  33. Remove the radiator assembly as follows:


    1. Disconnect the harness from the cooling fan ECU.
    2.  
    3. Remove the 4 bolts and radiator.
      NOTE
      Do not allow the cooler condenser and radiator to come into contact with each other.

    4.  
    5. Detach the 3 claws and remove the fan.
    6.  
    7. Remove the 2 radiator support cushions and 2 radiator lower supports from the radiator.
    8.  

  34.  

To install:

  1. Install the radiator assembly as follows:


    1. Install the 2 radiator support cushions and 2 radiator lower supports to the radiator.
    2.  
    3. Install the fan to the radiator, and attach the 3 claws.
    4.  
    5. Align the radiator with the condenser. Then install the radiator.
    6.  

  2.  
  3. Connect the radiator hose to the water inlet with thermostat and radiator tank upper.
  4.  
  5. Connect the radiator hose to the water inlet and radiator tank lower.
  6.  
  7. Install the upper radiator support sub-assembly.
  8.  
  9. Install the hood lock assembly.
  10.  
  11. Install the hood lock control cable cover.
  12.  
  13. Install the radiator support opening cover.
  14.  
  15. Refill the engine cooling system.
  16.  
  17. Check for engine coolant leaks.
  18.  
  19. Install the front bumper cover.
  20.  
  21. Install the air cleaner cap with air cleaner hose.
  22.  
  23. Install the No. 1 air cleaner inlet with the bolt and tighten to 44 inch lbs. (5 Nm).
  24.  
  25. Install the V-bank cover and tighten the 2 nuts to 44 inch lbs. (5 Nm).
  26.  
  27. Install the left and right engine room side covers.
  28.  
  29. Install the cool air intake duct seal.
  30.  
  31. Install the engine under cover.
  32.  
  33. Connect the negative battery cable.
  34.  
  35. Perform the system initialization procedure.
  36.  



Click image to see an enlarged view

Fig. Exploded view of the radiator assembly and related components.-SC 300

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any work.
  4.  
  5. Remove the engine under cover.
  6.  
  7. Drain engine coolant.
  8.  
  9. Remove the battery and battery tray.
  10.  
  11. Disconnect these hoses:

    Upper radiator hose from radiator
     
    Radiator reservoir hose from radiator
     
    Lower radiator hose from radiator
     
    2 oil cooler hoses for A/T from radiator. Plug the hose ends.
     

  12.  
  13. Remove the 2 clips, disconnect the claw of the No.2 fan shroud from the hook of the No.1 fan shroud, and remove the No.2 fan shroud.
  14.  
  15. Remove the 2 bolts, screw and upper radiator support. Remove the 2 upper radiator supports.
  16.  
  17. Lift out the radiator assembly.
  18.  
  19. Remove the 2 lower radiator supports.
  20.  
  21. Remove the 2 bolts and No. 1 fan shroud from the radiator.
  22.  
  23. Remove the 2 cushions from the No. 1 fan shroud.
  24.  

To install:

  1. Install the 2 cushions to the No. 1 fan shroud.
  2.  
  3. Install the 2 bolts and No. 1 fan shroud to the radiator.
  4.  
  5. Install the 2 lower radiator supports.
  6.  
  7. Install the radiator assembly into the vehicle.
  8.  
  9. Install the 2 upper radiator supports. Tighten the bolts to 9 ft. lbs. (12 Nm).

    Click image to see an enlarged view

    Fig. Inserting the claw to the hook as shown.-SC 300

  10.  
  11. Install the No. 2 fan shroud by connecting the claw of the No.2 fan shroud to the hook of the No.1 fan shroud and engaging the 2 clips.
  12.  
  13. Connect these hoses:

    2 oil cooler hoses for A/T to the radiator
     
    Lower radiator hose to the radiator
     
    Radiator reservoir hose to the radiator
     
    Upper radiator hose to the radiator
     

  14.  
  15. Install the battery tray and battery.
  16.  
  17. Refill the cooling system.
  18.  
  19. Check the A/T fluid level.
  20.  
  21. Install the engine under cover.
  22.  
  23. Connect the negative battery cable.
  24.  



Click image to see an enlarged view

Fig. Exploded view of the radiator assembly and related components.-SC 400

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any work.
  4.  
  5. Remove the engine under covers.
  6.  
  7. Drain engine coolant.
  8.  
  9. Remove the battery and battery tray.
  10.  
  11. Disconnect the following hoses:

    Upper radiator hose from radiator
     
    Radiator reservoir hose from radiator
     
    Lower radiator hose from radiator
     
    2 oil cooler hoses for A/T from radiator, Plug the hose ends.
     
    Union bolt and gasket, then disconnect the pressure hose from the hydraulic motor
     
    Return hose from the hydraulic motor
     

  12.  
  13. Remove the 2 bolts, brackets and bushings, and disconnect the cooling fan inlet pipe from the fan shroud.
  14.  
  15. Disconnect the suction hose from the clamp on the fan shroud.
  16.  
  17. Remove the 3 bolts, and disconnect the reservoir tank.
  18.  
  19. Disconnect the Engine Coolant Temperature (ECT) sensor connector and disconnect the wire clamp from the fan shroud.
  20.  
  21. Remove the 2 bolts, screw and upper radiator support. Remove the 2 upper radiator supports.
  22.  
  23. Slightly lift the radiator, and disconnect the 2 oil cooler hoses (for cooling fan) from the hose clamp on the radiator fan shroud.
  24.  
  25. Lift out the radiator assembly.
  26.  
  27. Remove the 2 lower radiator supports from the radiator.
  28.  
  29. Remove the 4 bolts and fan shroud from the radiator.
  30.  

To install:

  1. Install the fan shroud to the radiator with the 4 bolts and tighten to 43 inch lbs. (4.9 Nm).
  2.  
  3. Install the 2 lower radiator supports to the radiator.
  4.  
  5. Place the radiator assembly on the body bracket.
  6.  
  7. Slightly lift the radiator, and connect the 2 oil cooler hoses (for cooling fan) to the hose clamp on the radiator fan shroud.
  8.  
  9. Install the upper radiator support with the screw and 2 bolts. Install the 2 upper radiator supports. Tighten the bolts to 9 ft. lbs. (12 Nm).
  10.  
  11. Connect the ECT sensor connector and install the wire clamp to the fan shroud.
  12.  
  13. Install the reservoir tank with the 3 bolts and tighten to 43 inch lbs. (4.9 Nm).
  14.  
  15. Install the suction hose to the clamp on the fan shroud.
  16.  
  17. Install the cooling fan inlet pipe to the fan shroud with the 2 bushings, brackets and bolts. Tighten the bolts to 43 inch lbs. (4.9 Nm).
  18.  
  19. Install the battery tray and battery.
  20.  
  21. Connect the following hoses:

    Upper radiator hose to the radiator
     
    Radiator reservoir hose to the radiator
     
    Lower radiator hose to the radiator
     
    2 oil cooler hoses for A/T to the radiator
     
    Pressure hose to the hydraulic motor with a new gasket and union bolt. Tighten the union bolt to 47 ft. lbs. (64 Nm).
     
    Return hose to the hydraulic motor
     

  22.  
  23. Refill the cooling system.
  24.  
  25. Fill with cooling fan fluid.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Start the engine and check for leaks.
  30.  
  31. Recheck the engine coolant level.
  32.  
  33. Check the A/T fluid level.
  34.  
  35. Install the engine under covers.
  36.  



Click image to see an enlarged view

Fig. Exploded view of the radiator assembly and related components.-SC 430

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable. Wait at least 90 seconds before performing any work.
  4.  
  5. Remove the engine under cover.
  6.  
  7. Remove air cleaner inlet No. 1.
  8.  
  9. Drain engine coolant.
  10.  
  11. Remove the radiator reserve tank assembly.
  12.  
  13. Remove the V-bank cover.
  14.  
  15. Remove the intake air connector pipe.
  16.  
  17. Remove the air cleaner assembly.
  18.  
  19. Disconnect the radiator hoses No. 1 and No. 2.
  20.  
  21. Disconnect oil cooler inlet tube No. 1.
  22.  
  23. Disconnect oil cooler outlet tube No. 1.
  24.  
  25. Disconnect the cooling fan ECU connector.
  26.  
  27. Remove the 2 nuts and 2 radiator support brackets.
  28.  
  29. Remove the radiator and fan.
  30.  
  31. Remove the 2 grommets.
  32.  
  33. Disconnect the radiator reservoir hose from the radiator.
  34.  
  35. Remove the 6 bolts and fan assembly from the radiator.
  36.  

To install:

  1. Install the fan assy to the radiator with the 6 bolts and tighten to 44 inch lbs. (5 Nm).
  2.  
  3. Connect the radiator reservoir hose to the radiator.
  4.  
  5. Install the 2 grommets to the radiator.
  6.  
  7. Attach the 2 grommets on the radiator to the body bracket.
  8.  
  9. Install the radiator and fan with the 2 radiator support brackets and 2 nuts. Tighten the nuts to 10 ft. lbs. (13.5 Nm).
  10.  
  11. Connect the cooling fan ECU connector.
  12.  
  13. Connect oil cooler outlet tube No. 1.
  14.  
  15. Connect oil cooler inlet tube No. 1.
  16.  
  17. Connect the radiator hoses No. 1 and No. 2.
  18.  
  19. Install the air cleaner assembly.
  20.  
  21. Install the intake air connector pipe.
  22.  
  23. Install the radiator reserve tank assembly.
  24.  
  25. Refill the cooling system.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Start the engine and check for leaks.
  30.  
  31. Install air cleaner inlet No. 1.
  32.  
  33. Remove the V-bank cover.
  34.  
  35. Install the engine under cover.
  36.  
  37. Perform the system initialization procedure.
  38.  

 
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