Camry 2008-2009

Water Pump With Motor

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Removal & Installation




CAUTION
Before inspecting the high-voltage system or disconnecting the low voltage connector of the inverter with converter assembly, take safety precautions, such as wearing insulated gloves and removing the service plug grip to prevent electrical shocks. Make sure to turn the power switch off before removing the service plug grip. After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system. After disconnecting the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.

  1. Check for any present DTCs and record them.
    NOTE
    Confirm that P0AA6 (High voltage insulation is unusual) is not output before doing removal or installation work inside the battery. If the DTC is output, perform troubleshooting procedures first.

  2.  
  3. Release the 2 claws and remove the luggage trim service hole cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the service plug grip.
  8.  
  9. Remove the air cleaner assembly.
  10.  
  11. Remove the left engine room side cover as follows:
    1. Pull the A part upward to disengage the clip.
    2.  
    3. Pull the B parts upward by hand to disengage the 2 clips, and remove the No. 2 engine room side cover.

      Click image to see an enlarged view

      Fig. Remove the left engine room side cover

    4.  

  12.  
  13. Remove the inverter reserve tank cap.
  14.  
  15. Using a hexagon wrench (10 mm), remove the drain plug indicated in the illustration and drain the coolant.

    Click image to see an enlarged view

    Fig. Inverter drain plug location view

  16.  
  17. Remove the 2 bolts and connector cover assembly.
    CAUTION
    Do not touch the high voltage connectors and terminals for 10 minutes after the service plug grip is removed. Wear insulating gloves.


    WARNING
    Do not start the engine with the service plug grip removed because it may cause a malfunction.

  18.  
  19. Using the voltmeter, measure the voltage between the terminals of the 2 phase connectors (N-P).
  20.  
  21. Use measuring range of DC 750 V or more on the voltmeter. Standard voltage: should read 0 volts.

    Click image to see an enlarged view

    Fig. Measure the voltage between the terminals of the 2 phase

  22.  
  23. Separate the motor cable by removing 2 bolts (A) and then bolt (B).
  24.  
  25. While loosening bolt (B), disconnect the generator cable.
    NOTE
    Removing bolts (A) and (B) in a wrong order may cause the cable and the inverter with converter to break. Insulate the removed terminals with insulating tape. Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.

  26.  
  27. Disconnect the wire harness clamp.
  28.  
  29. Remove the 2 bolts and inverter reserve tank sub-assembly.
  30.  
  31. Disconnect the 2 water hoses from the inverter reserve tank sub-assembly.

    Click image to see an enlarged view

    Fig. Remove the bolts and hoses from the inverter reserve tank sub-assembly

  32.  
  33. Remove the reservoir tank bracket.
  34.  
  35. Remove the clip, and disconnect the water hose.
  36.  
  37. Disconnect the air conditioning harness assembly.
  38.  
  39. Disconnect the wire harness clamp.
  40.  
  41. Remove the bolt and disconnect the frame wire.
  42.  
  43. Disconnect the wire harness clamp.
  44.  
  45. Remove the inverter with converter assembly as follows:
    1. Move the outer section to the wire harness side as illustrated, then disconnect the circuit breaker sensor connector.
    2.  
    3. Disconnect the C58 connector.
    4.  
    5. Raise the lock lever and disconnect the A62 connector. Cover the hole where the connector was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.

      Click image to see an enlarged view

      Fig. Disconnect the C58 and the A62 connector

    6.  
    7. Disconnect the 2 wire harness clamps.
    8.  
    9. Remove the 2 bolts and No. 6 inverter bracket.
    10.  
    11. Remove the 3 bolts and inverter with converter assembly. Do not turn over the removed inverter with converter assembly.
    12.  

  46.  
  47. Remove the clip and disconnect the water hose from the water pump with motor and bracket assembly.
  48.  
  49. Disconnect the connector from the water pump with motor and bracket assembly.
  50.  
  51. Remove the bolt, 2 nuts and water pump with motor and bracket assembly.

    Click image to see an enlarged view

    Fig. Water pump with motor and related components

  52.  

To install:

  1. Install the water pump with motor and bracket assembly with the bolt and 2 nuts. Tighten to 7 ft. lbs. (10 Nm).
  2.  
  3. Connect the connector to the water pump with motor and bracket assembly.
  4.  
  5. Connect the water hose to the water pump with motor and bracket assembly with the clip.
  6.  
  7. Install the inverter with converter assembly as follows:
    1. Install the inverter with converter assembly with 3 bolts. Tighten the bolts to 9 ft. lbs. (12 Nm).
    2.  
    3. Install the No. 6 inverter bracket with the 2 bolts. Tighten the bolts to 7 ft. lbs. (10 Nm).
    4.  
    5. Connect the inverter with converter assembly connectors and lock the connector with the lock lever.
    6.  
    7. Connect the 2 wire harness clamps.
    8.  
    9. Connect the circuit breaker sensor connector.
    10.  
    11. Connect the frame wire to the inverter with converter assembly.
    12.  
    13. Connect the water hose with the clip.
    14.  

  8.  
  9. Install the No. 2 inverter bracket with 2 bolts. Tighten the bolts to 7 ft. lbs. (10 Nm).
  10.  
  11. Connect the 2 water hoses with the 2 clips to the reserve tank sub-assembly.
  12.  
  13. Install the inverter reserve tank sub-assembly with the 2 bolts. Tighten the bolts to 7 ft. lbs. (10 Nm).
  14.  
  15. Connect the generator cable. Tighten bolt (B) and insert the generator cable into the inverter with converter assembly. Tighten the bolts to 71 inch. lbs. (8 Nm).
  16.  
  17. Fix the generator cable to the inverter with converter assembly with 2 bolts (A). Tighten the bolts to 71 inch. lbs. (8 Nm). Tightening bolts A and B in a wrong order may cause the cable and the inverter with converter to break.
  18.  
  19. Connect the wire harness clamp.
  20.  
  21. Connect the motor cable. Tighten bolt (B) and insert the motor cable into the inverter with converter assembly. Tighten the bolts to 71 inch. lbs. (8 Nm).
  22.  
  23. Fix the motor cable to the inverter with converter assembly with 2 bolts (A). Tighten the bolts to 71 inch. lbs. (8 Nm).
  24.  
  25. Connect the wire harness clamp.
  26.  
  27. Install the air cleaner assembly.
  28.  
  29. Install the service plug grip.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Install the luggage trim service hole cover with the 2 claws.
  34.  
  35. Perform initialization procedure.
  36.  

 
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