Replacement [06/2015 - ]: Procedure

Refer to PROCEDURE - Step 7 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 7 [11/2018 - ]

Refer to PROCEDURE - Step 1 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 1 [11/2018 - ]

Refer to PROCEDURE - Step 2 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 2 [11/2018 - ]

Refer to PROCEDURE - Step 3 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 3 [11/2018 - ]

Refer to PROCEDURE - Step 17 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 17 [11/2018 - ]

WARNING:

• When the coolant (Toyota genuine FC stack coolant (Pre-mixed)) temperature is high, do not remove the radiator cap sub-assembly or the drain cock plug of the FC radiator, and do not disconnect the No. 2 FC cooling water pump outlet hose or No. 2 FC cooling water valve inlet hose.
• Fluid and steam may spray out due to high pressure, possibly resulting in burns.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Radiator Cap Sub-assembly	*2	FC Radiator Drain Cock Plug
*3	No. 2 FC Cooling Water Pump Outlet Hose	*4	No. 2 FC Cooling Water Valve Inlet Hose

1. Connect a hose with an inside diameter of 9 mm (0.354 in.) to the FC radiator assembly drain cock as shown in the illustration.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   HOSE

2. Loosen the FC radiator assembly drain cock plug.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Radiator Cap Sub-assembly
   *2	FC Radiator Drain Cock Plug

3. Remove the radiator cap sub-assembly, then drain the coolant (Toyota genuine FC stack coolant (Pre-mixed)).
   NOTE:

   In order to measure the volume of drained coolant (Toyota genuine FC stack coolant (Pre-mixed)), make sure to recover the coolant.

4. Tighten the FC radiator assembly drain cock plug by hand.
5. Remove the hose from the FC radiator assembly drain cock.
6. Disconnect the No. 2 FC cooling water valve inlet hose (with FC water hose connector).
   NOTE:

   Before disconnecting the No. 2 FC cooling water valve inlet hose, check that there is no mud or other contaminant on the No. 2 FC cooling water valve inlet hose or FC stack cooling water outlet pipe, and clean as necessary.

   1. Using a screwdriver with its tip wrapped in protective tape, press down the retainer of the FC water hose connector to release the lock.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *a	Protective Tape
      	Press Down

   2. Separate the No. 2 FC cooling water valve inlet hose (with FC water hose connector) from the FC stack cooling water outlet pipe, and drain the coolant (Toyota genuine FC stack coolant (Pre-mixed)).

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disconnect Slowly

      NOTE:

      • In order to measure the volume of drained coolant (Toyota genuine FC stack coolant (Pre-mixed)), make sure to recover the coolant.
      • Disconnect the components slowly to prevent coolant (Toyota genuine FC stack coolant (Pre-mixed)) from splattering.
      • Perform the procedures by hand. Do not use any tools.
      • Do not rotate or tilt the No. 2 FC cooling water valve inlet hose (with FC water hose connector) when pulling it out.
      • If the O-ring on the inner side of the FC water hose connector is damaged or falls out, replace the FC water hose connector with a new one.
   3. After the No. 2 FC cooling water valve inlet hose (with FC water hose connector) has been disconnected, check that there is no mud or other contaminant adhering to the sealing surface of the FC stack cooling water outlet pipe, and clean it as necessary.
   4. When working with the No. 2 FC cooling water valve inlet hose (with FC water hose connector) disconnected, to prevent foreign matter from entering, protect the connecting portions of the No. 2 FC cooling water valve inlet hose (with FC water hose connector) and FC stack cooling water outlet pipe with plastic bags.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *a	Plastic Bag

7. Disconnect the No. 2 FC cooling water pump outlet hose (with FC water hose connector).
   NOTE:

   Before disconnecting the No. 2 FC cooling water pump outlet hose, check that there is no mud or other contaminant on the No. 2 FC cooling water pump outlet hose or FC stack cooling water inlet pipe, and clean as necessary.

   1. Using a screwdriver with its tip wrapped in protective tape, press down the retainer of the FC water hose connector to release the lock.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *a	Protective Tape
      	Press Down

   2. Separate the No. 2 FC cooling water pump outlet hose (with FC water hose connector) from the FC stack cooling water inlet pipe, and drain the coolant (Toyota genuine FC stack coolant (Pre-mixed)).
      NOTE:

      • In order to measure the volume of drained coolant (Toyota genuine FC stack coolant (Pre-mixed)), make sure to recover the coolant.
      • Disconnect the components slowly to prevent coolant (Toyota genuine FC stack coolant (Pre-mixed)) from splattering.
      • Perform the work by hand. Do not use tools.
      • Do not rotate or tilt the No. 2 FC cooling water pump outlet hose (with FC water hose connector) when pulling it out.
      • If the O-ring on the inner side of the FC water hose connector is damaged or falls out, replace the FC water hose connector with a new one.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disconnect Slowly

   3. After the No. 2 FC cooling water pump outlet hose (with FC water hose connector) has been disconnected, check that there is no mud or other contaminant adhering to the sealing surface of the FC stack cooling water inlet pipe, and clean it as necessary.
   4. When working with the No. 2 FC cooling water pump outlet hose (with FC water hose connector) disconnected, to prevent foreign matter from entering, protect the connecting portions of the No. 2 FC cooling water pump outlet hose (with FC water hose connector) and FC stack cooling water inlet pipe with plastic bags.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *a	Plastic Bag

8. Connect the No. 2 FC cooling water pump outlet hose (with FC water hose connector).
   1. After working with the No. 2 FC cooling water pump outlet hose (with FC water hose connector) disconnected, remove the plastic bags that are protecting the connecting portions of the No. 2 FC cooling water pump outlet hose (with FC water hose connector) and FC stack cooling water inlet pipe.
   2. Line up the No. 2 FC cooling water pump outlet hose (with FC water hose connector) and FC stack cooling water inlet pipe in a row, and push them in as a single unit.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *a	No Identification Markings
      	Slowly Insert

      NOTE:

      • The No. 2 FC cooling water pump outlet hose (with FC water hose connector) and FC stack cooling water inlet pipe do not have identification markings.
      • If the O-ring on the inner side of the FC water hose connector is damaged or falls out, replace the FC water hose connector with a new one.
      • Do not rotate or tilt the No. 2 FC cooling water pump outlet hose (with FC water hose connector) when pushing it in.
      • Securely and fully insert the No. 2 FC cooling water pump outlet hose (with FC water hose connector) all the way into the FC stack cooling water inlet pipe.
   3. Push up the retainer of the FC water hose connector and lock it.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Push Up

      HINT: 

      The retainer of the FC water hose connector is designed so that it cannot be locked if the No. 2 FC cooling water pump outlet hose (with FC water hose connector) is not securely inserted into the FC stack cooling water inlet pipe.

   4. After connecting the No. 2 FC cooling water pump outlet hose (with FC water hose connector), firmly pull on the FC water hose connector and FC stack cooling water inlet pipe to check that they are securely connected.
9. Connect the No. 2 FC cooling water valve inlet hose (with FC water hose connector).
   1. After working with the No. 2 FC cooling water valve inlet hose (with FC water hose connector) disconnected, remove the plastic bags that are protecting the connecting portions of the No. 2 FC cooling water valve inlet hose (with FC water hose connector) and FC stack cooling water outlet pipe.
   2. Line up the No. 2 FC cooling water valve inlet hose (with FC water hose connector) and FC stack cooling water outlet pipe in a row, and push them in as a single unit.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      *a	Identification Markings (White)
      	Slowly Insert

      NOTE:

      • Align the white identification markings of the No. 2 FC cooling water valve inlet hose (with FC water hose connector) and the FC stack cooling water outlet pipe.
      • If the O-ring on the inner side of the FC water hose connector is damaged or falls out, replace the FC water hose connector with a new one.
      • Do not rotate or tilt the No. 2 FC cooling water valve inlet hose (with FC water hose connector) when pushing it in.
      • Securely and fully insert the No. 2 FC cooling water valve inlet hose (with FC water hose connector) all the way into the FC stack cooling water outlet pipe.
   3. Push up the retainer of the FC water hose connector and lock it.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Push Up

      HINT: 

      The retainer of the FC water hose connector is designed so that it cannot be locked if the No. 2 FC cooling water valve inlet hose (with FC water hose connector) is not securely inserted into the FC stack cooling water outlet pipe.

   4. After connecting the No. 2 FC cooling water valve inlet hose (with FC water hose connector), firmly pull on the FC water hose connector and FC stack cooling water outlet pipe to check that they are securely connected.

HINT: 

The coolant (Toyota genuine FC stack coolant (Pre-mixed)) capacity: 19.6 liters (20.7 US qts, 17.2 Imp. qts)

1. Connect the Techstream to the DLC3.
2. Turn the power switch on (IG).
3. Turn the Techstream on.
4. Enter the following menus: Powertrain / FC / Utility / FC Stack Coolant Air Bleeding

   Powertrain > FC > Utility 

   Tester Display
   FC Stack Coolant Air Bleeding

5. Following the instructions on the Techstream, perform the utility "FC Stack Coolant Air Bleeding".

   HINT: 

   • Coolant (Toyota genuine FC stack coolant (Pre-mixed)) filling is performed multiple times during the air bleeding procedure.
   • The FC cooling water air bleeding valve and heater air bleeding valve that appear in the procedures for air bleeding of the coolant (Toyota genuine FC stack coolant (Pre-mixed)) passages can be found at the locations shown in the illustration.

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

     *1

     FC Cooling Water Air-bleeding Valve

     *2

     Heater Air-bleeding Valve

   1. If the Techstream screen displays instructions to start filling coolant, use the following procedures to fill the coolant.
      NOTE:

      If coolant filling is not performed according to the following procedures, air bleeding may be insufficient, the electric water pump (heater water with motor pump assembly) may stop operating due to its self-protective function, and DTC B14C7 may be output.

      1. Using tools as shown in the illustration, make the preparations for coolant (Toyota genuine FC stack coolant (Pre-mixed)) filling and air bleeding.

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      2. Fill the coolant (Toyota genuine FC stack coolant (Pre-mixed)).

         HINT: 

         Fill coolant (Toyota genuine FC stack coolant (Pre-mixed)) until the fluid surface is higher than the locations of the FC cooling water air-bleeding valve and heater air-bleeding valve.

         Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

         *1	FC Cooling Water Air-bleeding Valve
         *2	Heater Air-bleeding Valve
         *a	Coolant (Toyota genuine FC stack coolant (Pre-mixed)) Fluid Surface

      3. Loosen the FC cooling water air-bleeding valve and heater air-bleeding valve and perform air bleeding until the coolant (Toyota genuine FC stack coolant (Pre-mixed)) flows out.

         HINT: 

         Because coolant (Toyota genuine FC stack coolant (Pre-mixed)) will overflow from the FC cooling water air-bleeding valve and heater air-bleeding valve, cover them with a piece of cloth so that coolant does not splatter.

      4. Close the FC cooling water air-bleeding valve and heater air-bleeding valve.
6. When the screen shown in the illustration is displayed, exit the Air Bleeding Utility.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

7. Turn the power switch on (IG).
8. Set the air conditioner panel temperature setting to MAX HOT.
9. Using the Techstream, enter the following menus: Body Electrical / Air Conditioner / Active Test / Heater Valve.

   Body Electrical > Air Conditioner > Active Test 

   Active Test Display
   Heater Valve

   Data List Display
   Electric Water Pump Speed

10. Using the Active Text, perform air bleeding.
    1. In the Active Test for the heater valve (3 way valve), repeat the following control sequence 2 or 3 times: set the valve to the open position, then to the half position, then to the close position, then to the half position again, and then back to the open position.[*1]
    2. Data List, check that the electric water pump (heater water with motor pump assembly) is rotating continuously.[*2]
       NOTE:

       If the electric water pump (heater water with motor pump assembly) is not rotating continuously, its self-protection function may have operated due to air bleeding being insufficient, and DTC B14C7 may have been stored.

    3. If insufficient air bleeding causes the electric water pump (heater water with motor pump assembly) to stop rotating, perform procedures [*1] through [*2].
    4. Clear the DTC.

       Refer to DTC CHECK / CLEAR [06/2015 - ]

    5. Check for DTC and make sure the normal system code is output.

       Refer to DTC CHECK / CLEAR [06/2015 - ]

11. Exit the Active Test.
12. Drive the vehicle to warm it up.
13. Leave the vehicle until the coolant (Toyota genuine FC stack coolant (Pre-mixed)) has cooled down.
14. Check the fluid level in the reserve tank when it is cool, and if the level has decreased, fill it to the specified quantity.

    HINT: 

    Until the fluid level in the reserve tank stops decreasing, repeat the sequence of warming, cooling, checking the level in the reserve tank and filling coolant (Toyota genuine FC stack coolant (Pre-mixed)).

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 10

Refer to PROCEDURE - Step 11

Refer to PROCEDURE - Step 12

Refer to PROCEDURE - Step 38 [06/2015 - 11/2018] , or refer to PROCEDURE - Step 38 [11/2018 - ]