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Installation [08/2019 - ]: Procedure

  1. INSTALL ENGINE MOUNTING BRACKET LH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting bracket LH is necessary.

    1. Install the engine mounting bracket LH to the vehicle body with the 8 bolts.
      GTY656365Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 71 N*m (724 kgf*cm, 52 ft.*lbf) 

      NOTE:

      Temporarily tighten the bolt (A), then tighten the bolt (B) before tightening the other 7 bolts.

    2. Engage the clamp to connect the wire harness to the engine mounting bracket LH.
  2. INSTALL ENGINE MOUNTING INSULATOR LH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

    1. Install the engine mounting insulator LH to the hybrid vehicle transaxle assembly with the 4 bolts.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

  3. INSTALL ENGINE MOUNTING SPACER 

    HINT: 

    Perform this procedure only when replacement of the engine mounting spacer is necessary.

    1. Install the engine mounting spacer to the vehicle body with the 2 bolts.

      Torque: 71 N*m (724 kgf*cm, 52 ft.*lbf) 

  4. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

    1. Install the engine mounting insulator sub-assembly RH to the engine mounting spacer and vehicle body with the nut and 2 bolts.

      Torque: 71 N*m (724 kgf*cm, 52 ft.*lbf) 

    2. Install the brake booster pump assembly with bracket.

      Refer to INSTALLATION [03/2018 - ]

  5. INSTALL REAR ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the rear engine mounting insulator is necessary.

    1. Install the rear engine mounting insulator to the front frame assembly with the 4 nuts.

      Torque: 71 N*m (724 kgf*cm, 52 ft.*lbf) 

    2. Install the 2 hole plugs to the front frame assembly.
  6. INSTALL FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

    Perform this procedure only when replacement of the front engine mounting insulator is necessary.

    1. Install the front engine mounting insulator to the front frame assembly with the 3 nuts.

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

    2. Install the hole plug to the front frame assembly.
  7. INSTALL ENGINE HANGERS 

    See step  63

  8. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND 
    1. Remove the engine assembly from the engine stand.
  9. INSTALL FLYWHEEL SUB-ASSEMBLY 
    1. Using height adjustment attachments and plate lift attachments, place the engine assembly on a flat level surface.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, keep the engine assembly horizontal.
      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments under the No. 2 oil pan sub-assembly of the engine assembly.
      • Using an engine sling device and engine lift, secure the engine assembly before servicing.
    2. Install the flywheel sub-assembly.

      Refer to PROCEDURE - Step 2

  10. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  11. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY 
    1. Using height adjustment attachments and plate lift attachments to keep the hybrid vehicle transaxle assembly level, set an engine lifter underneath the hybrid vehicle transaxle assembly.
      NOTE:
      • Using rope, attachments or equivalent tools, firmly secure the hybrid vehicle transaxle assembly to the engine lifter.
      • Using an engine sling device and engine lift, secure the engine assembly before servicing.
    2. Install the hybrid vehicle transaxle assembly.

      Refer to PROCEDURE - Step 11

  12. INSTALL NO. 3 AUTOMATIC TRANSMISSION CASE COVER 

    Refer to PROCEDURE - Step 13

  13. INSTALL MOTOR CABLE BRACKET 

    Refer to PROCEDURE - Step 14

  14. INSTALL REAR ENGINE MOUNTING BRACKET 

    Refer to PROCEDURE - Step 15

  15. INSTALL FRONT FRAME ASSEMBLY 
    1. Temporarily install the front engine mounting insulator with front frame assembly to the front engine mounting bracket with the bolt.
    2. Install the rear engine mounting insulator to the rear engine mounting bracket with the bolt.
      GTY657327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Rib

      Torque: 71 N*m (724 kgf*cm, 52 ft.*lbf) 

      NOTE:

      If tightening the bolt before installation of the front frame assembly, ensure that the edge of the protrusion of the bracket is within the width of the rib.

    3. Fully tighten the bolt of the front engine mounting insulator.

      Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

  16. INSTALL STEERING LINK ASSEMBLY 

    Refer to PROCEDURE - Step 3

  17. INSTALL FRONT STABILIZER BAR 

    Refer to PROCEDURE - Step 4

  18. INSTALL FRONT NO. 2 STABILIZER BRACKET LH 

    Refer to PROCEDURE - Step 5

  19. INSTALL FRONT NO. 2 STABILIZER BRACKET RH 

    HINT: 

    Perform the same procedure as for the LH side.

  20. INSTALL FRONT NO. 1 STABILIZER BRACKET LH 

    Refer to PROCEDURE - Step 7

  21. INSTALL FRONT NO. 1 STABILIZER BRACKET RH 

    HINT: 

    Perform the same procedure as for the LH side.

  22. INSTALL ENGINE WIRE 
    1. Connect all connectors and clamps, and install the engine wire to the engine assembly with transaxle.
  23. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2) 

    Refer to PROCEDURE - Step 2

  24. INSTALL EXHAUST MANIFOLD ASSEMBLY LH (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 3

  25. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 6

  26. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1) 

    Refer to PROCEDURE - Step 12

  27. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 13

  28. INSTALL NO. 2 EGR PIPE GASKET 

    Refer to PROCEDURE - Step 8

  29. INSTALL EGR INLET GASKET 

    Refer to PROCEDURE - Step 2

  30. INSTALL EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 3

  31. CONNECT NO. 6 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 4

  32. CONNECT WATER BY-PASS HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 5

  33. CONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 6

  34. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 

    HINT: 

    Perform "Inspection After Repair" after replacing the engine assembly.

    Refer to INITIALIZATION [10/2015 - ]

    1. Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front frame assembly level, set an engine lifter underneath the engine assembly with transaxle and front frame assembly.
      NOTE:
      • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
      • To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.
    2. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.
    3. Install the wire harness bracket to the engine assembly with the bolt.

      Torque: 16.5 N*m (168 kgf*cm, 12 ft.*lbf) 

    4. Engage the clamp to connect the wire harness to the wire harness bracket.
    5. Operate the engine lifter and install the engine assembly with transaxle to the vehicle.
      WARNING:

      Do not raise the engine assembly with transaxle more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

      NOTE:
      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
      • While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.
    6. Install the frame side rail plate sub-assembly RH and frame side rail plate sub-assembly LH to the front frame assembly and vehicle body with the 6 bolts and 2 nuts.
      GTY656617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Bolt (A) 

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      Bolt (B) and Nut (A) 

      Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) 

    7. Install the front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH to the front frame assembly and vehicle body with the 6 bolts and 2 nuts.

      Bolt (C) 

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      Bolt (D) and Nut (B) 

      Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) 

    8. Install the engine mounting insulator sub-assembly RH to the front No. 1 engine mounting bracket LH with the 2 bolts and 2 nuts.

      Bolt and Nut (A) 

      Torque: 71 N*m (724 kgf*cm, 52 ft.*lbf) 

      Nut (B) 

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

      GTY662882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Install the No. 2 engine mounting stay RH with the bolt and 2 nuts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

    10. Install the engine mounting bracket LH to the engine mounting insulator LH with the bolt and nut.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

      NOTE:

      Tighten the bolt while holding the nut in place.

  35. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover to the hybrid vehicle transaxle assembly with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  36. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET 
    1. Install the No. 1 exhaust pipe support bracket to the oil pan sub-assembly with the 2 bolts.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  37. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 52

  38. INSTALL FRONT DRIVE SHAFT ASSEMBLY 

    Refer to INSTALLATION [10/2015 - ]

  39. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 13

  40. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 11

  41. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 23

  42. CONNECT NO. 1 FUEL HOSE 
    1. Connect the 2 No. 1 fuel hoses to the fuel pipes.

      Refer to PRECAUTION [12/2017 - ]

    2. Install the No. 2 fuel pipe clamp to the fuel tube connector.

      Refer to PRECAUTION [12/2017 - ]

  43. CONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  44. CONNECT DISCHARGE HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  45. INSTALL RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 11

  46. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 12

  47. CONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Connect the No. 1 fuel vapor feed hose to the No. 1 vacuum switching valve assembly and slide the clip to secure it.
  48. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose to the water inlet pipe and slide the clip to secure it.
  49. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose to the water outlet and slide the clip to secure it.
    2. Engage the clamp.
  50. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the water inlet with thermostat sub-assembly and slide the clip to secure it.
  51. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.
    2. Install the No. 1 radiator hose to the radiator pipe clamp.
  52. CONNECT WIRE HARNESS 
    1. Connect the No. 2 earth wire to the wire harness bracket with the bolt.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

    2. Engage the clamp and connect the engine wire to the vehicle body.
    3. Engage the claw and connect the engine wire to the engine room relay block assembly.
    4. Engage the 3 clamps.
    5. Connect the 3 connectors to the engine room relay block assembly.
    6. Connect the engine wire to the vehicle body with the bolt.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

  53. INSTALL ECM ASSEMBLY 

    Refer to PROCEDURE - Step 3

  54. CONNECT INLET MOTOR HOSE 

    Refer to PROCEDURE - Step 22

  55. CONNECT NO. 1 MOTOR COOLING HOSE 

    Refer to PROCEDURE - Step 23

  56. INSTALL BATTERY CARRIER SUB-ASSEMBLY 
    1. Install the battery carrier sub-assembly with the 6 bolts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

    2. Engage the clamp to connect the wire harness to the battery carrier sub-assembly.
  57. INSTALL INVERTER TRAY BRACKET SUB-ASSEMBLY 
    1. Install the inverter tray bracket sub-assembly with the 5 bolts.
      GTY665805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

      NOTE:

      Temporarily tighten the 2 bolts (A), (E) and then fully tighten the 5 bolts in the order of (B), (A), (C), (D) and (E).

    2. Engage the clamp to connect the outlet No. 1 inverter cooling hose to the inverter tray bracket sub-assembly.
  58. INSTALL INVERTER WITH CONVERTER ASSEMBLY 

    Refer to INSTALLATION [08/2016 - ]

  59. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 4 [10/2015 - 07/2021] , or refer to PROCEDURE - Step 4 [07/2021 - ]

  60. ADD HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 2

  61. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 4

  62. BLEED BRAKE SYSTEM 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH or engine mounting spacer is necessary.

    Refer to BLEEDING [08/2018 - ]

  63. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 4

  64. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  65. WARM UP COMPRESSOR 

    Refer to PROCEDURE - Step 3

  66. INSPECT SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 2

  67. ADJUST SHIFT LEVER POSITION 

    Refer to ADJUSTMENT [10/2015 - ]

  68. INSPECT FOR ENGINE OIL LEAK 

    Refer to PROCEDURE - Step 5 [10/2015 - 07/2021] , or refer to PROCEDURE - Step 5 [07/2021 - ]

  69. INSPECT FOR HYBRID TRANSAXLE FLUID LEAK 
  70. INSPECT FOR COOLANT LEAK (for Inverter) 

    Refer to PROCEDURE - Step 1

  71. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1

  72. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 4

  73. INSPECT FOR FUEL LEAK 

    Refer to ON-VEHICLE INSPECTION [12/2017 - ]

  74. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 8

  75. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1

  76. INSPECT HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 1

  77. INSPECT COOLANT LEVEL IN RESERVE TANK (for Inverter) 

    Refer to PROCEDURE - Step 2

  78. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK (for Engine) 

    Refer to PROCEDURE - Step 2

  79. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 5

  80. INSTALL FRONT FENDER APRON SEAL LH 
    1. Install the front fender apron seal LH to the vehicle body with the 2 bolts and clip.
  81. INSTALL FRONT FENDER APRON SEAL RH 
    1. Install the front fender apron seal RH to the vehicle body with the 2 bolts and clip.
  82. INSTALL NO. 2 ENGINE UNDER COVER 
    1. Install the No. 2 engine under cover to the front frame assembly with the 2 bolts, 2 screws and clip.
  83. INSTALL SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper) 

    Refer to PROCEDURE - Step 1

  84. INSTALL FRONT LOWER BUMPER ABSORBER 
    1. Engage the 2 claws and install the front lower bumper absorber to the vehicle body with the 4 screws and 2 clips.
  85. INSTALL NO. 1 ENGINE UNDER COVER 
    1. Install the No. 1 engine under cover to the vehicle body with the 3 bolts, 4 screws and clip.
  86. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 
    1. Install the front wheel opening extension pad RH to the No. 1 engine under cover with the 2 screws.
  87. INSTALL NO. 3 ENGINE UNDER COVER 
    1. Install the No. 3 engine under cover to the vehicle body with the 5 bolts, 2 screws and 2 clips.
  88. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 
    1. Install the front wheel opening extension pad LH to the No. 3 engine under cover with the 2 screws.
  89. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Engage the 4 clips in the order shown in the illustration to install the V-bank cover sub-assembly.
      NOTE:
      • Securely engage the clips.
      • If the clips are forcibly engaged or struck with an object, they may be damaged.
      GTY657464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. INSTALL FRONT WHEELS 

    Refer to INSTALLATION [10/2015 - ]

  91. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  92. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [03/2018 - ]

  93. PERFORM INITIALIZATION 

    Refer to PROCEDURE - Step 12

  94. INSPECT IGNITION TIMING 

    Refer to PROCEDURE - Step 8

  95. INSPECT ENGINE IDLE SPEED 

    Refer to PROCEDURE - Step 9

  96. INSPECT CO/HC 

    Refer to PROCEDURE - Step 11

  97. CHECK FOR SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [08/2018 - ]

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