Bypass Valve and hose (16260-F0010) received from Toyota today, with an install time of 1.5 hours.
I did not make a video, but I did take pictures along the way, so I hope that this helps others that are attempting to tackle on their own . I am not a certified auto mechanic but am an aircraft mechanic, so I am no stranger to working in constricted areas. This is how I removed and installed this part. I did not use the manual, as it is pretty straight fwd. I can't see why the dealer would charge so much for this
Here we go!
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Common hand Tool used :
Flat Head Screw driver
3/8 Ratchet
10mm and 12mm socket
Pliers
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Looking at the back portion of the valve.
There are the two 12mm bolts that need removed. Remove Bottom bolt first. once this is out you can maneuver that valve out of the way enough to get to the top bolt then remove.
I did not disconnect the wire connector on the coolant valve until the bolts were out. did this so that you can manipulate it enough to see the clip on the wire connector and depress without breaking.
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Next remove the 10mm bolt from the bracket that supports the O2 sensor wire. Note: take caution when removing this as it is torqued on there pretty good, the bracket started to bend a little before the bolt broke loose. if you can zoom in there is a small groove at the top that this sits in so be mindful when reinstalling this. once disconnected just set to the side out of your way.
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Disengage the white C clip from the top of the valve.
this clip to me seemed extremely flimsy so be gentle while pushing it back. I did use my small flat head to put into the back side of the clip (arrow shows location) and gently give it some pressure to disengage the clip. Once clip is disengaged apply small pressure (to the valve) and the hose connection will separate from the valve.
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(Upper Hose Clamp)
From there I moved onto the dreaded clamps for the upper/lower hose. as other have stated you can not fit your head in there. I was able to position my left arm on the back side of the engine bay and get my pliers on the clamp with some patience and several attempts finally was able to pull it back enough to be able to loosen the hose. I did not pull off the hose as fluid would be everywhere, so I just loosened it enough until I was ready on the bottom. I was trying to limit the fluid loss.
on the installation I was able to get my right hand on the back side of the clamp and slide the clamp back over to end of the hose and in the orange mark area on the hose all while squeezing the clamp with my left hand. good luck.
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(Lower Hose Clamp)
I tried laying across the engine, but that was not working. This is what I did and I did not have to remove the left front tire, the fender well cover or the battery. if you look on the left bottom part of the engine bay laying on the ground aft of the left front tire there is a small enough gap to access the lower hose and get some tools in there to remove the clamp. it will be a crap shoot to know which way the clamp was installed for each vehicle, but my clamp ears were facing down as seen in the picture and I was able to easily grab loosen and then get ready for the disconnection.
At this point Both metal clamps are off, white clip and connection point on valve is disconnected.
There are two plastic hose clips on the lower part of the line. One down by the lower clamp (just a C looking clamp support) and then half way up the line where two other lines are running parallel with the coolant hose.
Be gentle with this one as it is thin. I used my flat head added some light pressure on the plastic clamp top side center and it comes apart. The coolant hose is in the center position and will need to be fed through this clamp when removed then reverse this process on the installation.
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Amount of fluid that was captured in the pan after hoses where disconnected. I bought two gallons of fluid, but only used about 3/4 of the bottle to fill everything back up. so did not need the second bottle. everything is topped off. maintenance advisory on dash is gone. Heat and AC are solid.
RAV is Back to operational status.
Overall, most difficult was the top clamp, I lucked out on the lower side. I did leave with some battle wounds.
but overall not that difficult, just need a lot of patience.
Hope this helps someone out there. Let me know if anyone has any questions.
Also, if this pictures are unclear and you want to see more detailed ones I can repost them.
Thanks!
www.toyotanation.com
