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Section 291 (Cooling System): Thermostat: Replacement

WARNING: This page is about a different car, the 2004 Lexus RX 330. However, it is still accessible from the selected car via links, so may be relevant.
  1. DRAIN ENGINE COOLANT (See  ENGINE COOLANT  ) 
  2. REMOVE BATTERY 
  3. REMOVE AIR CLEANER CAP SUB-ASSY (See step 11 in  REPLACEMENT  ) 
  4. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSY 
  5. REMOVE AIR CLEANER INLET NO. 2 (See  REPLACEMENT  ) 
  6. REMOVE AIR CLEANER CASE (See  REPLACEMENT  ) 
  7. REMOVE AIR CLEANER BRACKET (See  REPLACEMENT  ) 
  8. REMOVE AIR CLEANER INLET NO. 1 (See  REPLACEMENT  ) 
  9. REMOVE STARTER ASSY (TMMWV MADE) (See  REPLACEMENT  ) 
  10. REMOVE WATER INLET PIPE (TMC MADE) 
    1. Remove the bolt and the water inlet pipe.
    2. Remove the O-ring from the water inlet pipe.
      Fig 1: Removing Bolt And Water Inlet Pipe (TMC Made)
      G03006871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE WATER INLET (TMC MADE) 
    1. Disconnect the wire harness clamp.
    2. Remove the 3 nuts and the water inlet.
      Fig 2: Removing Water Inlet (TMC Made)
      G03006872Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE WATER INLET (TMMWV MADE) 
    1. Disconnect the wire harness clamp.
    2. Remove the bolt and 3 nuts, then remove the water inlet.
      Fig 3: Removing Water Inlet (TMMWV Made)
      G03006873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE THERMOSTAT 
  14. INSTALL THERMOSTAT 
    1. Install a new gasket to the thermostat.
    2. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.

      HINT:

      The jiggle valve may be set within 15° of either side of the prescribed position.

      Fig 4: Installing Thermostat
      G03006874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL WATER INLET (TMC MADE) 

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

  16. INSTALL WATER INLET PIPE (TMC MADE) 
    1. Install a new O-ring to the water inlet pipe.
    2. Apply soapy water to the O-ring.
    3. Connect the water inlet pipe to the water inlet.
    4. Install the bolt which is used to fix the water inlet pipe to the cylinder head.

      Torque: 20 N.m (199 kgf.cm, 14 ft.lbf) 

  17. INSTALL WATER INLET (TMMWV MADE) 

    Torque: 

    • Nut 8.0 N.m (82 kgf.cm, 71 in.lbf) 
    • Bolt 20 N.m (199 kgf.cm, 14 ft.lbf) 
  18. INSTALL STARTER ASSY (TMMWV MADE) (See  REPLACEMENT  ) 
  19. INSTALL AIR CLEANER INLET NO. 1 (See  REPLACEMENT  ) 
  20. INSTALL AIR CLEANER BRACKET (See  REPLACEMENT  ) 
  21. INSTALL AIR CLEANER CASE (See  REPLACEMENT  ) 
  22. INSTALL AIR CLEANER INLET NO. 2 (See  REPLACEMENT  ) 
  23. INSTALL AIR CLEANER CAP SUB-ASSY (See  REPLACEMENT  ) 
  24. ADD ENGINE COOLANT (See  ENGINE COOLANT  ) 
  25. CHECK FOR ENGINE COOLANT LEAKS (See  ON-VEHICLE INSPECTION   and  INSPECTION  ) 
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