Lexus RX300 (MCU15). Service manual - part 188

CO06L–05

B04241

10

°

CO1267

Lock Plate

Lock Plate

Core

CO0317

f Normal X Twisted

X Twisted

O–Ring

B04236

Tap

WRONG

CORRECT

Tank

Lock
Plate

CO1206

Dimension ”B”

Stopper Bolt

Overhaul Handle

Punch Assembly

Part ”A”

SST

–

COOLING

RADIATOR

CO–21

LEXUS RX300   (RM785E)

REASSEMBLY

1.

INSTALL OIL COOLER TO LOWER TANK

(a)

Install 2 new O–rings to the oil cooler.

(b)

Install the oil cooler to the lower tank with the 2 plate
washers and nuts.
Torque: 8.3 N·m (85 kgf·cm, 74 in.·lbf)

(c)

Install the cooler pipe in the direction indicated in the il-
lustration.
Torque: 14.7 N·m (150 kgf·cm, 11 ft·lbf)

2.

INSPECT LOCK PLATE FOR DAMAGE

HINT:

S

If the sides of the lock plate groove are deformed, reas-
sembly of the tank will be impossible.

S

Therefore, first correct any deformation with pliers or simi-
lar object. Water leakage will result if the bottom of the
lock plate groove is damaged or dented.

NOTICE:
The radiator can only be recaulked 2 times. After the 2nd
time, the radiator core must be replaced.
3.

INSTALL NEW O–RINGS AND TANKS

(a)

After checking that there are no foreign objects in the lock
plate groove, install the new O–ring without twisting it.

HINT:
When cleaning the lock plate groove, lightly rub it with sand pa-
per without scratching it.

(b)

Install the tank without damaging the O–ring.

(c)

Tap the lock plate with a soft–faced hammer so that there
is no gap between it and the tank.

4.

ASSEMBLE SST
SST

09230–01010, 09231–14010

(a)

Install the punch assembly to the overhaul handle, insert-
ing it in the hole in part ”A” as shown in the illustration.

(b)

While gripping the handle, adjust the stopper bolt so that
dimension ”B” is as shown in the illustration.
Dimension: 8.4 mm (0.331 in)

B04239

5

SST

Lock

1

6

4

8

2

7

3

Plate

Stopper

Bolt

Tank

B04249

B04238

B04237

H

CO–22

–

COOLING

RADIATOR

LEXUS RX300   (RM785E)

5.

CAULK LOCK PLATE

(a)

Lightly press SST against the lock plate in the order
shown in the illustration. After repeating this a few times,
fully caulk the lock plate by squeezing the handle until
stopped by the stopper plate.
SST

09230–01010

HINT:

S

Do not stake the areas protruding around the pipes,
brackets or tank ribs.

S

The points shown in the illustration and oil cooler near
here cannot be staked with the SST. Use pliers or similar
object and be careful not to damage the core plates.

(b)

Check the lock plate height (H) after completing the caulk-
ing.
Plate height: 7.40 – 7.80 mm (0.2913 – 0.3071 in.)

If not within the specified height, adjust the stopper bolt of the
handle again and caulk again.
6.

INSTALL NO.1 WATER TEMPERATURE SWITCH

(a)

Install a new O–ring to the No.1 water temperature switch.

(b)

Install the No.1 water temperature switch.

B04240

SST

S01713

Tank

Lock

O–Ring

Plate

–

COOLING

RADIATOR

CO–23

LEXUS RX300   (RM785E)

7.

INSTALL DRAIN PLUG

(a)

Install a new O–ring to the drain plug.

(b)

Install the drain plug.

8.

INSPECT FOR WATER LEAKS

(a)

Plug the inlet and outlet pipes of the radiator with SST.
SST

09230–01010

(b)

Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (1.8 kgf/cm

2

, 26 psi)

(c)

Submerge the radiator in water.

(d)

Inspect for leaks.

HINT:
On radiators with resin tanks, there is a clearance between the
tank and lock plate where a minute amount of air will remain,
giving the appearance of an air leak when the radiator is sub-
merged in water. Therefore, before doing the water leak test,
first swish the radiator around in the water until all air bubbles
disappear.

CO0IJ–01

CO–24

–

COOLING

RADIATOR

LEXUS RX300   (RM785E)

INSTALLATION

Installation is in the reverse order of removal (See page CO–19).