HEATER ASSEMBLY > INSTALLATION

for Preparation Click here



1. INSTALL HEATER AND ACCESSORY ASSEMBLY



I104945E01

  1. Set the heater and accessory assembly into the vehicle.

  1. Tighten the 2 bolts and connect the heater exhaust pipe.

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }

  1. Install the heater and accessory assembly with the 4 nuts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf } for nut*1

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf } for nut*2



2. INSTALL AIR DUCT


I104944

  1. Install the air duct with the 2 clips.



3. INSTALL WINDSHIELD WASHER JAR ASSEMBLY


I104943

  1. Engage the claw and install the windshield washer jar.



4. CONNECT HEATER WATER INLET HOSE E


I104948E01

  1. Install the heater water inlet hose onto the engine assembly.

    HINT:
    Perform the installation with the hose clip and mark at the correct angle.



5. CONNECT HEATER WATER OUTLET HOSE


I104912E02

  1. Install the heater water outlet hose onto the heater unit.

    HINT:
    Perform the installation with the hose clip and mark at the correct angle.



6. INSTALL NO. 1 HOSE TO HOSE TUBE


I104949E01

  1. Install the hose to hose tube with the 2 bolts.

    Torque:
    7.8 N*m{ 80 kgf*cm , 69 in.*lbf }

  1. Install the hose to hose tube onto the vacuum pump and brake booster.

    HINT:
    Perform the installation with the hose clip and mark at the correct angle.



7. INSTALL HEATER PUMP ASSEMBLY



I104950E01

  1. Install the heater pump with the nut.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }

  1. Install the fuel hose onto the fuel tube.

    *1
    		A
    		*7
    		2 to 7 mm (0.079 to 0.276 mm)
    *2
    		B
    		*8
    		10°
    *3
    		View A
    		*9
    		30°
    *4
    		View B
    		*10
    		-3 to 0 mm (-0.118 to 0 mm)
    *5
    		30°
    		*11
    		2 to 6 mm (0.079 to 0.236 mm)
    *6
    		-3 to 0 mm (-0.118 to 0 mm)
    		-

    HINT:
    Perform the installation with the hose clip and mark at the correct angle.



8. INSTALL FUEL FILTER ASSEMBLY


    A202865

  1. Install the fuel filter with the 2 nuts.

    Torque:
    19 N*m{ 189 kgf*cm , 14 ft.*lbf }



    A202864

  1. Connect the 2 fuel hose clamps to the fuel filter.

  1. Connect the 2 fuel hoses to the fuel filter.



    A202202

  1. Connect the 2 connectors.



    A202203

  1. Connect the 2 wire harness clamps.

  1. Connect the connector.



9. INSTALL BATTERY TRAY


10. INSTALL BATTERY


11. INSTALL BATTERY CLAMP SUB-ASSEMBLY


A198368

  1. Install the battery clamp with the 2 nuts.

    Torque:
    3.5 N*m{ 36 kgf*cm , 31 in.*lbf }



12. INSTALL EXHAUST PIPE SUB-ASSEMBLY


I104939

  1. Install the bolt and 2 nuts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



13. INSTALL TAIL EXHAUST PIPE ASSEMBLY

  1. Install the tail exhaust pipe assembly (Click here).



14. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

  1. Install the windshield wiper motor and link assembly (Click here).



15. ADD ENGINE COOLANT

  1. Tighten the radiator drain cock plug.



    A201604E01

  1. Loosen the air bleed valve 1 and the air bleed valve 2.
    Text in Illustration 
    *1
    		Air Bleed Valve 1
    *2
    		Air Bleed Valve 2

  1. Add TOYOTA Super Long Life Coolant (SLLC).

    Standard Capacity:
    Item
    		Capacity
    w/ Combustion Type Power Heater
    		4.9 liters (5.2 US qts, 4.3 Imp. qts)

    NOTICE:
    Never use water as a substitute for engine coolant.

    HINT:
    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).



    A202523E01

  1. Add coolant to B line of the radiator reserve tank.
    Text in Illustration 
    *1
    		B Line

  1. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
    If the coolant level is low, add coolant.



    A201604E01

  1. Tighten the air bleed valve 1 and the air bleed valve 2.
    Text in Illustration 
    *1
    		Air Bleed Valve 1
    *2
    		Air Bleed Valve 2

  1. Start the engine, maintain the speed at 3000 rpm for 10 seconds, and idle the engine for 10 seconds. Repeat the same procedure above 4 more times.

  1. Install the reserve tank cap sub-assembly.

  1. Loosen the air bleed valve 1 and the air bleed valve 2.

  1. Add 350 cc (21.3 cu in.) coolant.

  1. Tighten the air bleed valve 1 and the air bleed valve 2.

  1. Start the engine and warm it up.

  1. Bleed air from the cooling system.

    NOTICE:
    1. Before starting the engine, turn the A/C switch off.
    2. Adjust the air conditioning temperature setting to MAX (HOT).
    3. Adjust the air conditioning blower setting to LO.


    1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.

      HINT:
      Thermostat opening timing can be determined by squeezing the inlet radiator hose, and sensing vibrations when the engine coolant starts to flow inside the hose.

      CAUTION:
      When squeezing the radiator hoses:
      1. Wear protective gloves.
      2. Be careful as the radiator hoses are hot.
      3. Keep your hands away from the radiator fan.

  1. Stop the engine, and wait until the engine coolant cools down.



    A202523E02

  1. After the engine has cooled down, check that the coolant level is between the FULL and LOW lines.
    If the coolant level is low, add coolant to the reservoir tank FULL line.
    Text in Illustration 
    *1
    		FULL Line
    *2
    		LOW Line



16. INSPECT FOR COOLANT LEAK

CAUTION:
To avoid the danger of being burned, do not remove the radiator cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.



    A201603E01

  1. Fill the radiator assembly with engine coolant, and attach a radiator cap tester.
    Text in Illustration 
    *1
    		Radiator Cap Tester

  1. Pump the tester to 118 kPa (1.2 kgf/cm2, 17.1 psi), and then check that the pressure does not drop.
    If the pressure drops, check the hoses, radiator assembly and water pump assembly for leaks. If there are no signs or traces of external engine coolant leaks, check the heater core, cylinder block and head.



17. INSPECT FOR FUEL LEAK

  1. Connect an intelligent tester to the DLC3.

  1. Turn the ignition switch to ON.

  1. Turn the tester on.

  1. Enter the following menus: Powertrain / Engine / Active Test.

  1. Perform the Active Test.

    Intelligent Tester Display
    		Test Details
    		Control Range
    		Diagnostic Notes
    Test the Fuel Leak
    		Pressurize common rail internal fuel pressure, and check for fuel leaks
    		Stop/Start
    		Perform inspection of the high pressure fuel system.
    Test is possible when the following conditions are met:
    1. Warmed up engine.
    2. Vehicle is stopped.
    3. Battery voltage is 12 V or more.
    4. PM regeneration is not operating.
    5. Engine speed is less than 4000 rpm.
    Results of real-vehicle check:
    1. Engine Speed: 2702 rpm
    1. Fuel Pressure: 108570 kPa
    1. Target Common Rail Pressure: 105500 kPa
    1. Target Pump SCV Current: 1.2 A
    1. MAP: 127 kPa
    1. MAF: 28 g/sec.



18. BLEED AIR FROM FUEL SYSTEM

HINT:
Bleed air from fuel system (Click here).



19. WARM UP ENGINE

NOTICE:
Warm up the engine at less than 2000 rpm for 1 minute or more after charging it with refrigerant.



20. INSPECT FOR EXHAUST GAS LEAK