LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2020 >> LS 500h AWD >> Repair and Diagnosis >> Engine Mechanical >> Cooling System (Mechanical) >> Engine Cooling System - Service Information (2 Of 2) >> Radiator >> Installation [09/2019 - 10/2020] >> Procedure

Installation [09/2019 - 10/2020]: Procedure

  1. INSTALL NO. 5 RADIATOR SUPPORT TO SEAL 
    1. Install a new No. 5 radiator support to seal to the radiator assembly.
  2. INSTALL NO. 4 RADIATOR SUPPORT TO SEAL 
    1. Install a new No. 4 radiator support to seal to the radiator assembly.
  3. INSTALL NO. 3 RADIATOR SUPPORT TO SEAL 
    1. Install a new No. 3 radiator support to seal to the radiator assembly.
  4. INSTALL NO. 2 RADIATOR SUPPORT TO SEAL 
    1. Install a new No. 2 radiator support to seal to the radiator assembly.
  5. INSTALL NO. 1 RADIATOR SUPPORT TO SEAL 
    1. Upper Side:
      1. Install a new No. 1 radiator support to seal to the radiator assembly.
    2. Lower Side:
      1. Install a new No. 1 radiator support to seal to the radiator assembly.
  6. INSTALL LOWER RADIATOR SUPPORT 
    1. Install the 2 lower radiator supports to the radiator assembly.
  7. INSTALL SUB-RADIATOR SUPPORT CUSHION 
    1. Install the 2 radiator support cushions to the radiator assembly.
  8. INSTALL FAN WITH MOTOR ASSEMBLY 
    1. Attach the guide.
      GTY824295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the fan with motor assembly to the radiator assembly with the 2 bolts.
      NOTE:

      Do not damage the radiator assembly when installing the fan with motor assembly.

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

  9. INSTALL INVERTER WATER PUMP ASSEMBLY (WITH MOTOR) 
    1. Install the inverter water pump assembly (with motor) with the 2 bolts.

      Torque: 7.0 N.m (71 kgf/cm, 62 in.lbf) 

  10. INSTALL NO. 5 ENGINE ROOM WIRE 
    1. Attach the clamps and connect the connector to install the No. 5 engine room wire.
  11. INSTALL NO. 2 INVERTER COOLING HOSE 
    1. Install the No. 2 inverter cooling hose to the inverter water pump assembly (with motor), and slide the hose clip to secure the hose.
      NOTE:
      • Install so that the No. 2 inverter cooling hose paint mark and inverter water pump assembly (with motor) positioning stopper are securely overlapped. (Rotational Direction)
      • Make sure the No. 2 inverter cooling hose is securely inserted to the stopper. (Axial Direction)
    2. Attach the clamp.
    3. Install the No. 2 inverter cooling hose to the radiator assembly with the 2 clips.
      GTY824334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 105°
      *c 45° *d Paint Mark
      *e Upper Side *f Front Side
      *g Rotational Direction *h OK
      *i NG *j Variation Range
      *k Axis Direction *l Stopper
      *m 2 to 7 mm (0.0787 to 0.276 in.) - -
      Hose Clip Clip
  12. INSTALL NO. 2 RADIATOR HOSE 
    1. Install the No. 2 radiator hose to the radiator assembly, and slide the clip to secure the hose.
      NOTE:

      Install so that the No. 2 radiator hose paint mark and radiator assembly positioning stopper are securely overlapped. (Rotational Direction)

      HINT: 

      The clip may be installed facing either up or down.

    2. Attach the clamp.
      GTY787244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Radiator Hose *2 No. 3 Radiator Hose
      *a View A *b 120°
      *c 18° *d Paint Mark
      *e Radiator Side Rib *f Upper Side
      *g LH Side *h Rotational Direction
      *i OK *j NG
      *k Variation Range *l Axis Direction
      *m Stopper *n 2 to 5 mm (0.0787 to 0.197 in.)
      *o 0 to 1 mm (0 to 0.0394 in.) - -
  13. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE RH 
    1. Attach the claw to install the rear radiator side air guide plate RH to the radiator assembly.
      GTY824294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL DISCHARGE HOSE SUB-ASSEMBLY 
    1. Attach the clamp to install the discharge hose sub-assembly to the fan with motor assembly.
  15. INSTALL NO. 1 RADIATOR HOSE 
    1. Install the No. 1 radiator hose to the radiator assembly, and slide the clip to secure the hose.
      NOTE:

      Install so that the No. 1 radiator hose paint mark and radiator assembly positioning stopper are securely overlapped. (Rotational Direction)

    2. Attach the clamp.
      GTY775699Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c 18° *d Paint Mark
      *e Upper Side *f LH Side
      *g Rotational Direction *h OK
      *i NG *j Variation Range
      *k Axis Direction *l Stopper
      *m 2 to 5 mm (0.0787 to 0.197 in.) *n 0 to 1 mm (0 to 0.0394 in.)
  16. INSTALL NO. 3 INVERTER COOLING HOSE 
    1. Install the No. 3 inverter cooling hose to the radiator assembly with the clip and bolt.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

      GTY809608Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Clip
      Bolt
    2. Attach the clamps.
  17. INSTALL REAR RADIATOR SIDE AIR GUIDE PLATE LH 
    1. Attach the claw and install the rear radiator side air guide plate LH to the radiator assembly.
      GTY819017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL RADIATOR RESERVE TANK HOSE 
    1. Install the radiator reserve tank hose to the radiator assembly, and slide the clip to secure the hose.
      NOTE:
      • Install so that the radiator reserve tank hose paint mark and radiator assembly positioning stopper are securely overlapped. (Rotational Direction)
      • Make sure the radiator reserve tank hose is securely inserted to the stopper. (Axial Direction)
      GTY803631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c Paint Mark *d Upper Side
      *e LH Side *f Rotational Direction
      *g OK *h NG
      *i Variation Range *j Axis Direction
      *k Stopper *l 2 to 7 mm (0.0787 to 0.276 in.)
  19. INSTALL RADIATOR ASSEMBLY 
    1. Install the radiator assembly together with the fan with motor assembly to the vehicle.
      NOTE:
      • Perform the following procedure with 2 or more people to prevent damage to the radiator assembly.
      • Do not damage the radiator assembly, fan with motor assembly, cooler pipe or cooling hoses when installing them.
      GTY820799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction - -
  20. INSTALL COOLER CONDENSER ASSEMBLY 
    1. Insert the cooler condenser assembly into the vehicle and attach the guide.
      NOTE:

      When inserting the cooler condenser assembly, do not damage the cooler condenser assembly and radiator assembly.

    2. Attach the claw to install the cooler condenser assembly.
      GTY791918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Install in this Direction - -
    3. Install the No. 2 inverter cooling hose and No. 3 inverter cooling hose to the cooler condenser assembly, and slide the clip to secure the hose.
      NOTE:
      • Install so that the No. 2 inverter cooling hose and No. 3 inverter cooling hose paint mark and cooler condenser assembly positioning stopper are securely overlapped. (Rotational Direction)
      • Make sure the No. 2 inverter cooling hose and No. 3 inverter cooling hose is securely inserted to the stopper. (Axial Direction)
      GTY819207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Inverter Cooling Hose *2 No. 3 Inverter Cooling Hose
      *a View A *b 120°
      *c Paint Mark *d Upper Side
      *e LH Side *f Rotational Direction
      *g OK *h NG
      *i Variation Range *j Axis Direction
      *k Stopper *l 2 to 7 mm (0.0787 to 0.276 in.)
  21. CONNECT DISCHARGE HOSE SUB-ASSEMBLY 
  22. CONNECT LIQUID TUBE SUB-ASSEMBLY A 

    Refer to PROCEDURE - Step 3

  23. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY 
    1. Install the upper radiator support sub-assembly with the 5 bolts.

      Torque: 12.5 N.m (127 kgf/cm, 9 ft.lbf) 

  24. INSTALL HOOD LOCK CONTROL CABLE COVER RH 
    1. Attach the clamp to connect the hood lock control cable cover LH.
    2. Install the screw.
  25. INSTALL HOOD LOCK CONTROL CABLE COVER LH 
    1. Attach the clamp to connect the hood lock control cable cover RH.
    2. Install the screw.
  26. CONNECT ENGINE ROOM MAIN WIRE 
    1. Attach the clamps to connect the engine room main wire.
    2. Connect the connector.
  27. CONNECT NO. 3 INVERTER COOLING HOSE 
    1. Install the No. 3 inverter cooling hose to the inverter cooling pipe, and slide the clip to secure the hose.
      NOTE:
      • Install so that the No. 3 inverter cooling hose paint mark and inverter cooling pipe positioning stopper are securely overlapped. (Rotational Direction)
      • Make sure the No. 3 inverter cooling hose is securely inserted to the stopper. (Axial Direction)
      GTY793960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c Paint Mark *d Upper Side
      *e RH Side *f Rotational Direction
      *g OK *h NG
      *i Variation Range *j Axis Direction
      *k Stopper *l 2 to 7 mm (0.0787 to 0.276 in.)
  28. CONNECT NO. 3 RADIATOR HOSE 
    1. Connect the No. 3 radiator hose to the water inlet with thermostat sub-assembly, and slide the clip to secure the hose.
      NOTE:

      Install so that the No. 3 radiator hose paint mark and water inlet with thermostat sub-assembly positioning stopper are securely overlapped. (Rotational Direction)

    2. Attach the clamps.
      GTY824370Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Radiator Hose *2 No. 3 Radiator Hose
      *a View A *b 120°
      *c 29° *d Paint Mark
      *e Upper Side *f Rear Side
      *g Rotational Direction *h OK
      *i NG *j Variation Range
      *k Axis Direction *l Stopper
      *m 2 to 6 mm (0.0787 to 0.236 in.) *n 0 to 1 mm (0 to 0.0394 in.)
  29. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the water outlet sub-assembly, and slide the clip to secure the hose.
      NOTE:

      Install so that the No. 1 radiator hose paint mark and water outlet sub-assembly positioning stopper are securely overlapped. (Rotational Direction)

      GTY818930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c 48° *d Paint Mark
      *e Upper Side *f Rear Side
      *g Rotational Direction *h OK
      *i NG *j Variation Range
      *k Axis Direction *l Stopper
      *m 2 to 6 mm (0.0787 to 0.236 in.) *n 0 to 1 mm (0 to 0.0394 in.)
  30. CONNECT OIL COOLER INLET HOSE 
    1. Connect the oil cooler inlet hose to the radiator pipe, and slide the clip to secure the hose.
      GTY968851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Radiator Pipe
      *a Hold Area
      *b Net Protector
      NOTE:

      Do not install the oil cooler inlet hose while holding the net protector. If force is applied to the net protector, it may cause the oil cooler inlet hose to crack and lead to engine coolant leaks.

  31. CONNECT TRANSMISSION OIL COOLER HOSE 
    1. Connect the transmission oil cooler hose to the radiator assembly, and slide the clip to secure the hose.
    2. Attach the clamp.
  32. CONNECT NO. 2 OIL COOLER OUTLET HOSE 
    1. Connect the No. 2 oil cooler outlet hose to the radiator assembly, and slide the clip to secure the hose.
  33. INSTALL INVERTER RESERVE TANK ASSEMBLY 
    1. Install the inverter reserve tank assembly to the fan with motor assembly with the 2 bolts.

      Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

      GTY836710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 1 inverter cooling hose to the inverter water pump assembly (with motor), and slide the clip to secure the hose.
      NOTE:
      • Install so that the No. 1 inverter cooling hose paint mark and inverter water pump assembly (with motor) positioning stopper are securely overlapped. (Rotational Direction)
      • Make sure the No. 1 inverter cooling hose is securely inserted to the stopper. (Axial Direction)
      GTY786691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Inverter Cooling Hose - -
      *a View A *b 60°
      *c 210° *d 5°
      *e Paint Mark *f Rear Side
      *g LH Side *h Rotational Direction
      *i OK *j NG
      *k Variation Range *l Axis Direction
      *m Stopper *n 2 to 7 mm (0.0787 to 0.276 in.)
    3. Install the No. 6 inverter cooling hose to the inverter coling pipe, and slide the clip to secure the hose.
      NOTE:
      • Install so that the No. 6 inverter cooling hose paint mark and inverter cooling pipe positioning stopper are securely overlapped. (Rotational Direction)
      • Make sure the No. 6 inverter cooling hose is securely inserted to the stopper. (Axial Direction)
      GTY798988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 6 Inverter Cooling Hose - -
      *a View A *b 120°
      *c 7° *d Paint Mark
      *e Upper Side *f RH Side
      *g Rotational Direction *h OK
      *i NG *j Variation Range
      *k Axis Direction *l Stopper
      *m 2 to 7 mm (0.0787 to 0.276 in.) - -
  34. INSTALL RADIATOR RESERVE TANK ASSEMBLY 
    1. Install the radiator reserve tank assembly to the fan with motor assembly with the 2 bolts.

      Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

      GTY818088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the clamp.
      GTY818091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the connector and attach the clamps.
      GTY818092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the reserve tank outlet hose, and slide the clip to secure the hose to the radiator pipe.
      GTY777360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Radiator Pipe
    5. Connect the radiator reserve tank hose, and slide the clip to secure the hose to the reserve tank assembly.
      NOTE:
      • Install so that the radiator reserve tank hose paint mark and reserve tank assembly positioning stopper are securely overlapped. (Rotational Direction)
      • Make sure the radiator reserve tank hose is securely inserted to the stopper. (Axial Direction)
      GTY828584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c 45° *d Paint Mark
      *e Upper Side *f Rear Side
      *g Rotational Direction *h OK
      *i NG *j Variation Range
      *k Axis Direction *l Stopper
      *m 2 to 7 mm (0.0787 to 0.276 in.) - -
  35. INSTALL HIGH PITCHED HORN ASSEMBLY 

    Refer to PROCEDURE - Step 2

  36. INSTALL LOW PITCHED HORN ASSEMBLY 

    Refer to PROCEDURE - Step 1

  37. INSTALL HOOD LOCK ASSEMBLY 

    Refer to PROCEDURE - Step 1

  38. INSTALL HOOD LOCK RELEASE LEVER PROTECTOR 

    Refer to PROCEDURE - Step 2

  39. INSTALL LOWER ARM BRACKET BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 10

  40. INSTALL LOWER ARM BRACKET BRACE SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 9

  41. INSTALL VEHICLE APPROACHING SPEAKER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  42. INSTALL AIR CLEANER WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 4

  43. INSTALL NO. 1 AIR CLEANER INLET 

    Refer to PROCEDURE - Step 5

  44. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  45. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 7

  46. INSTALL FRONT BUMPER 
  47. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 9

  48. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 7

  49. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 5

  50. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 3

  51. INSPECT FOR COOLANT LEAK (for Inverter) 

    Refer to PROCEDURE - Step 1

  52. INSTALL LOWER RADIATOR AIR DEFLECTOR 

    Refer to PROCEDURE - Step 8

  53. INSTALL UPPER RADIATOR SUPPORT SEAL 

    Refer to PROCEDURE - Step 9

  54. INSTALL RADIATOR COVER PLATE 

    Refer to PROCEDURE - Step 10

  55. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 151

  56. INSTALL STRUT BAR BRACKET SUPPORT SUB-ASSEMBLY (for 4WD) 

    Refer to PROCEDURE - Step 138

  57. INSTALL FRONT SUSPENSION MEMBER BRACE (for 4WD) 

    Refer to PROCEDURE - Step 139

  58. INSTALL OIL PAN PROTECTOR (for 2WD) 

    Refer to PROCEDURE - Step 15

  59. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY 
  60. INSPECT FOR COOLING FAN MOTOR 

    Refer to Cooling Fan Circuit [10/2017 - ]

scientia non olet · About LEMON Manuals