WATER PUMP INSTALLATION


  1. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. A01FVQ8E01

      Install a new water pump gasket and the engine water pump with the 16 bolts.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt B, C
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
      Text in Illustration
      A01FTNO Bolt A
      A01FRJI Bolt B
      A01FRV5 Bolt C

      Note


      • Be sure to apply adhesive to the 2 bolts labeled C before reusing them, or replace them with new ones if necessary.

        Adhesive
        Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

      • Make sure that there is no oil on the threads of the bolts labeled A.

      Standard Length
      Item Length
      Bolt A 55 mm (2.17 in.)
      Bolt B, C 22 mm (0.87 in.)

  2. INSTALL WATER INLET ASSEMBLY


    1. Install a new No. 1 water inlet housing gasket and water outlet pipe O-ring.

    2. Install the water inlet assembly with the 4 bolts and nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Be careful not to allow the O-ring to get caught between parts.

    3. Connect the 4 hoses.

  3. INSTALL WATER PUMP PULLEY


    1. Temporarily install the pulley with the 4 bolts.

    2. A01FT1FE03

      Using SST, hold the pulley and tighten the 4 bolts.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  4. INSTALL NO. 2 ENGINE COVER


    1. Install the No. 2 engine cover with the 3 clips.

    2. Connect the clamp.

  5. INSTALL INJECTOR DRIVER

    Note


    • Be careful not to drop or strike the injector driver.

    • The injector driver is grounded at the bolt and nut. To make sure that it is grounded, clean all oil and foreign matter from the installation areas of the injector driver and engine before installing the injector driver.


    1. Install the injector driver with the bolt and 2 nuts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01FT7SE01
      Text in Illustration
      *1 Lock Lever

      Connect the 4 connectors to the injector driver. Move the lock levers in the direction indicated by the arrow to lock the 3 connectors.

  6. INSTALL NO. 1 ENGINE COVER


    1. Install the No. 1 engine cover with the 3 clips.

  7. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the water inlet with thermostat sub-assembly and secure it with the clip.

  8. INSTALL NO. 1 RADIATOR HOSE


    1. Install the No. 1 radiator hose and secure it with the 2 clamps.

  9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01FVJNE01

      Temporarily install the V-ribbed belt tensioner with the 5 bolts.

      Standard Bolt
      Item Length
      A 70 mm (2.76 in.)
      B 35 mm (1.38 in.)

    2. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

    3. Tighten the other bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  10. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY


    1. A01FUAP

      Using an E8 "TORX" socket, install the compressor with motor assembly with the stud bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A01FSUEE01

      Install the compressor with motor assembly with the 2 bolts and nut.

      Torque:
      for bolt
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }
      for nut
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration to install the compressor with motor assembly.

  11. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. Remove the attached vinyl tape from the No. 1 cooler refrigerant discharge hose.

    2. Apply sufficient compressor oil (ND-OIL 11) to a new O-ring and the fitting surface of the compressor with motor assembly.

      Compressor oil
      ND-OIL 11 or equivalent

    3. Install the O-ring on the No. 1 cooler refrigerant discharge hose.

    4. Install the No. 1 cooler refrigerant discharge hose on the compressor with motor assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  12. CONNECT SUCTION HOSE


    1. Remove the attached vinyl tape from the suction hose.

    2. Apply sufficient compressor oil (ND-OIL 11) to a new O-ring and the fitting surface of the compressor with motor assembly.

      Compressor oil
      ND-OIL 11 or equivalent

    3. Install the O-ring on the suction hose.

    4. Install the suction hose on the compressor with motor assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  13. INSTALL FAN AND GENERATOR V BELT


    1. A01FRBKE01
      Text in Illustration
      *1 Engine Water Pump
      *2 Tensioner
      *3 Crankshaft

      Set the fan and generator V belt onto every part.

    2. While turning the belt tensioner counterclockwise, remove the 5 mm bi-hexagon wrench.

      Note


      • Put the backside of the fan and generator V belt on the tensioner pulley and idler pulley.

      • Check that the fan and generator V belt is properly set to each pulley.

    3. If it is difficult to install the fan and generator V belt, perform the following procedure.


      1. Put the fan and generator V belt on every part except the tensioner pulley.

      2. Put the fan and generator V belt on the tensioner pulley while turning the belt tensioner counterclockwise.

        Note


        • Put the backside of the fan and generator V belt on the tensioner pulley and idler pulley.

        • Check that the fan and generator V belt is properly set to each pulley.

    4. Check that the belt fits properly in the ribbed grooves.

      Tech Tips

      Make sure to check by hand that the belt has not slipped out of the grooves on the bottom of the pulley.

  14. INSTALL ECM


    1. Install the ECM with the 2 nuts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

      Any parts that have scratches, dents, etc., or that are dropped or subjected to a strong impact during servicing need to be replaced with new one.

    2. A01FTIV

      Connect the 2 ECM connectors and wire clamp.

      Note


      • When connecting the connectors, make sure that dirt, water or other foreign matter does not become stuck between the connectors and other parts.

      • Make sure that the 2 levers are securely locked.

    3. for LHD:

      Connect the clamp.

    4. for RHD:

      Connect the 2 clamps.

  15. INSTALL SERVICE PLUG GRIP

    CAUTION:

    Wear insulated gloves.

    Note

    Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.

    A01FTIGE01
    Text in Illustration
    *1 Lever - -

    1. Install the service plug grip in the order shown in the illustration.


      1. Insert the service plug grip and rotate the lever.

      2. Slide the lever until a click sound is heard to lock the lever.

  16. INSTALL LOWER HYBRID VEHICLE BATTERY COVER PANEL

    CAUTION:

    Perform work using insulated gloves and insulated tools.


    1. A01FVY2E01
      Text in Illustration
      *1 Arrow

      Install the lower hybrid vehicle battery cover panel with the 4 nuts.

      Tech Tips

      Be sure to install the lower hybrid vehicle battery cover panel with its arrow facing upwards.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  17. INSTALL NO. 1 SEAT ARMREST CAP


    1. Attach the 4 guides and 4 claws to install the No. 1 seat armrest cap.

  18. CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  19. INSTALL LUGGAGE COMPARTMENT TRIM COVER LH


    1. Install the luggage compartment trim cover.

  20. INSTALL LUGGAGE COMPARTMENT FLOOR MAT


    1. Install the luggage compartment floor mat.

  21. ADD ENGINE COOLANT

    CAUTION:

    Do not remove the radiator cap or reservoir tank cap while the engine and radiator are still hot. Pressurized hot engine coolant and steam may be released and cause serious burns.

    Tech Tips

    Before starting the engine to warm up the engine, turn the A/C switch off.


    1. Tighten the 2 cylinder block drain cock plugs.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    2. Tighten the radiator drain cock plug.

    3. Remove the reservoir tank cap and radiator cap.

    4. A01FTHOE01
      Text in Illustration
      *1 B Line

      Add coolant through the radiator reservoir tank filler opening until the coolant reaches the "B" line and install the reservoir tank cap.

      Standard Capacity
      Radiator Core Thickness [mm] Specified Condition
      16 9.4 liters (9.9 US qts, 8.3 Imp. qts)
      27 9.9 liters (10.5 US qts, 8.7 Imp. qts)

      Note

      Never use water as a substitute for engine coolant.

      Tech Tips

      TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

    5. Add engine coolant to the coolant filler opening and install the radiator cap.

      Tech Tips

      Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.

    6. Put the engine in inspection mode Click here. [*1]

    7. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes. [*2]

      CAUTION:


      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the radiator fans.

      Note


      • Immediately after starting the engine, if the radiator reservoir tank does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant.

      • Do not start the engine when there is no coolant in the radiator reservoir tank.

      • Make sure that the needle does not show an abnormally high temperature.

      • If there is not enough coolant, the engine may overheat.

      Tech Tips


      • Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.

      • The thermostat open timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    8. Stop the engine, and wait until the engine coolant cools down to ambient temperature. [*3]

    9. Check the coolant level in the radiator reservoir tank. [*4]

      Tech Tips


      • If the coolant level is below the "Low" line, add coolant through the radiator reservoir tank filler opening until the coolant reaches the "B" line and repeat steps [*1] through [*4].

      • If the coolant level is above the "FULL" line, drain coolant until the coolant level is between the "FULL" and "LOW" line.

  22. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


    1. for HFC-134a (R134a):

      Click here

    2. for HFO-1234yf (R1234yf):

      Click here

  23. INSPECT FOR COOLANT LEAK

    CAUTION:

    Do not remove the radiator cap or reservoir tank cap while the engine and radiator are still hot. Pressurized hot engine coolant and steam may be released and cause serious burns.

    Note

    Before performing each inspection, turn the A/C switch off.


    1. Remove the reservoir tank cap.

    2. Fill the radiator with coolant and attach a radiator cap tester.

    3. Put the engine in inspection mode Click here.

    4. Warm up the engine.

    5. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 20 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and engine water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

  24. WARM UP COMPRESSOR


    1. for HFC-134a (R134a):

      Click here

    2. for HFO-1234yf (R1234yf):

      Click here

  25. CHECK FOR REFRIGERANT GAS LEAK


    1. for HFC-134a (R134a):

      Click here

    2. for HFO-1234yf (R1234yf):

      Click here

  26. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the screw.

  27. INSTALL ENGINE UNDER COVER


    1. Install the engine under cover with the 13 screws and 3 clips.

  28. INSTALL NO. 1 AIR CLEANER INLET


    1. Install the No. 1 air cleaner inlet with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  29. INSTALL COOL AIR INTAKE DUCT SEAL


    1. Install the cool air intake duct seal with the 7 clips.

  30. INSTALL ENGINE ROOM SIDE COVER


    1. Install the engine room side cover with the 4 clips.

  31. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A01FTDYE01
      Text in Illustration
      *1 Tip (Round Portion)

      Attach the 3 clips in the order shown in the illustration to install the V-bank cover.

      Note


      • Securely attach the clips.

      • If the clips are forcibly attached or struck with an object, they may be damaged.

      • Do not apply any oil to the tips (round portions).

  32. PERFORM INITIALIZATION

    Click here