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Installation [07/2022 - ]: Procedure

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  1. INSTALL ENGINE HANGER 

    See step  1

  2. REMOVE ENGINE FROM ENGINE STAND 
    1. Remove the engine assembly from the engine stand.
  3. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY 

    Refer to PROCEDURE - Step 4

  4. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  5. INSTALL ENGINE ASSEMBLY 

    Refer to PROCEDURE - Step 13

  6. INSTALL ENGINE WIRE 
    1. Connect all the connectors and clamps, and install the engine wire to the engine assembly with transaxle.
    2. Install the bolt.
      GTY785254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Install the 3 bolts.
      GTY785253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    4. Install the bolt.
      GTY785252Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    5. Install the 3 bolts.
      GTY801324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  7. INSTALL HV AIR CONDITIONING WIRE 

    Refer to PROCEDURE - Step 16

  8. INSTALL NO. 2 FUEL VAPOR FEED PIPE 
    1. Install the No. 2 fuel vapor feed pipe to the fuel hose bracket and wire harness clamp bracket with the bolt and nut.

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

  9. INSTALL FLYWHEEL HOUSING SIDE COVER 
    1. Install the flywheel housing side cover to the cylinder block sub-assembly.
      GTY800671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL STARTER HOLE INSULATOR 

    Refer to PROCEDURE - Step 15

  11. 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. Temporarily install the engine mounting insulator sub-assembly RH to the vehicle.
      Fig 1: Engine Mounting Insulator Sub-Assembly RH Tightening Sequence
      GTY811791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporarily Tighten
    2. Install the 2 bolts and nut in the order shown in the illustration.

      Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

    3. Connect the air conditioner tube and accessory assembly with the bolt and nut.

      Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

    4. Install the No. 2 earth wire to the engine mounting insulator sub-assembly RH and vehicle with the 2 bolts.

      Torque: 10.5 N.m (107 kgf/cm, 8 ft.lbf) 

  12. INSTALL ENGINE MOUNTING INSULATOR LH 

    HINT: 

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

    1. Temporarily install the engine mounting insulator LH to the vehicle.
      Fig 2: Engine Mounting Insulator LH Tightening Sequence
      GTY832507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Temporarily Tighten
    2. Install the 4 bolts and nut in the order shown in the illustration.

      Torque: 42 N.m (428 kgf/cm, 31 ft.lbf) 

  13. REMOVE ENGINE HANGER 

    Refer to PROCEDURE - Step 59

  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front suspension crossmember sub-assembly level, set an engine lifter underneath the engine assembly with transaxle and front suspension crossmember sub-assembly.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle horizontal.
      • 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 oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.
    2. 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.
    3. Connect the front suspension crossmember sub-assembly to the vehicle with the 6 bolts.

      Torque: 141 N.m (1438 kgf/cm, 104 ft.lbf) 

    4. Apply adhesive to 2 or 3 threads of bolt.
      GTY806048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    5. Install the No. 2 engine mounting stay LH with the bolt.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    6. Install the engine mounting insulator LH to the hybrid vehicle transaxle assembly with the 3 bolts and nut.

      Bolt 

      Torque: 70 N.m (714 kgf/cm, 52 ft.lbf) 

      Nut 

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

    7. Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 2 bolts and nut.

      Bolt 

      Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

      Nut 

      Torque: 41 N.m (418 kgf/cm, 30 ft.lbf) 

  15. INSTALL NO. 1 SIDE RAIL REINFORCEMENT LH 

    Refer to PROCEDURE - Step 19

  16. INSTALL NO. 1 SIDE RAIL REINFORCEMENT RH 

    HINT: 

    Use the same procedure as for the LH side.

  17. INSTALL DRIVE SHAFT ASSEMBLY 

    Refer to INSTALLATION [10/2018 - ]

  18. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 

    Refer to PROCEDURE - Step 8

  19. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  20. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 8

  21. INSTALL COLUMN HOLE COVER SILENCER SHEET 

    Refer to PROCEDURE - Step 9

  22. CONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  23. CONNECT DISCHARGE HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  24. CONNECT NO. 3 WATER BY-PASS HOSE 
    1. Engage the clamp to install the No. 3 water by-pass hose.
  25. CONNECT WATER BY-PASS HOSE 
    1. Connect the water by-pass hose to the No. 3 water by-pass pipe and slide the hose clip to secure it.
  26. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube sub-assembly to the fuel pump assembly.

      Refer to PRECAUTION [10/2018 - ]

    2. Engage the clamp to connect the fuel tube sub-assembly.
  27. CONNECT OUTLET HEATER WATER HOSE 
    1. Align the protrusions of the outlet heater water hose connector with the cutouts in the water hose sub-assembly and push them together until the outlet heater water hose connector makes a "click" sound.
      GTY767363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Push in the retainer.
      GTY807804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Push
      Push in
    3. Check that the water hose sub-assembly and outlet heater water hose connector are securely connected by pulling on them.
  28. CONNECT INLET HEATER WATER HOSE 
    1. Align the protrusion of the water hose sub-assembly with the cutout in the inletheater water hose connector and push them together until the inlet heater water hose makes a "click" sound.
      GTY765348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Push in the retainer.
      GTY782078Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Push
      Push in
    3. Check that the water hose sub-assembly and inlet heater water hose connector are securely connected by pulling on them.
    4. Connect the connector.
  29. INSTALL FUEL DELIVERY GUARD 
    1. Install the fuel delivery guard to the engine mounting bracket RH with the bolt.

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

  30. INSTALL FUEL VAPOR FEED PIPE 
    1. Install the fuel vapor feed pipe to the fuel delivery guard with the bolt.

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

    2. Engage the clamp to connect the No. 1 fuel vapor feed hose.
    3. Engage the clamp to install the engine wire with the bolt.

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

  31. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 1

  32. INSTALL NO. 1 FUEL VAPOR FEED HOSE 
    1. Align the No. 1 fuel vapor feed hose connector with the No. 2 fuel vapor feed pipe, and push them together until the No. 1 fuel vapor feed hose connector makes a "click" sound.
      NOTE:
      • Check that there is no foreign matter on the connecting parts.
      • After connecting the No. 1 fuel vapor feed hose connector, check that the No. 2 fuel vapor feed pipe and No. 1 fuel vapor feed hose connector are securely connected by pulling on them.
  33. CONNECT OUTLET NO. 1 HYBRID WATER PUMP HOSE 
    1. Connect the outlet No. 1 hybrid water pump hose to the motor cooling cooler and slide the clip to secure it.
  34. CONNECT INLET HYBRID RADIATOR HOSE 
    1. Connect the inlet hybrid radiator hose to the motor cooling cooler and slide the clip to secure it.
  35. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the water inlet sub-assembly and slide the clip to secure it.
    2. Engage the 3 clamps to connect the No. 1 inverter cooling hose assembly and hybrid water pump inlet hose to the fan shroud assembly.
  36. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.
    2. Engage the clamp to connect the No. 1 radiator hose.
  37. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Install the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.
    2. Install the transmission control cable assembly to the control shaft lever with the nut.

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

  38. INSTALL INVERTER RESERVE TANK ASSEMBLY 
    1. Connect the No. 2 inverter cooling hose to the inverter reserve tank assembly and slide the clip to secure it.
    2. Connect the No. 5 inverter cooling hose to the inverter reserve tank assembly and slide the clip to secure it.
    3. Install the inverter reserve tank assembly with the 2 bolts.

      Torque: 5.0 N.m (51 kgf/cm, 44 in.lbf) 

  39. INSTALL INVERTER WITH CONVERTER ASSEMBLY 

    Refer to INSTALLATION [10/2018 - ]

  40. CONNECT ENGINE WIRE 
    1. Engage the 3 clamps to connect the engine wire to the vehicle.
    2. Connect the engine wire to the vehicle with the 2 bolts.

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

    3. Engage the 2 claws to connect the engine wire to the engine room relay block.
    4. Install the nut.

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

    5. Engage the 2 claws to connect the engine wire to the engine room relay block.
    6. Connect the 3 connectors to the engine room relay block.
  41. INSTALL NO. 1 RELAY BLOCK COVER 
    1. Engage the 2 guides and claw to install the No. 1 relay block cover to the engine room relay block.
  42. INSTALL ECM 

    Refer to INSTALLATION [10/2018 - ]

  43. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Install the air cleaner case sub-assembly with the 3 bolts.

      Torque: 4.0 N.m (41 kgf/cm, 35 in.lbf) 

  44. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  45. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 3

  46. INSTALL NO. 1 AIR CLEANER INLET 
    1. Install the No. 1 air cleaner inlet to the upper radiator support sub-assembly and air cleaner case sub-assembly with the 4 bolts.

      Torque: 4.0 N.m (41 kgf/cm, 35 in.lbf) 

  47. INSTALL RADIATOR SUPPORT OPENING COVER 

    Refer to PROCEDURE - Step 2

  48. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Engage the 4 clips to install the No. 1 engine cover sub-assembly.
      GTY819937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Securely engage the clips.
      • If the clips are forcibly engaged or struck with an object, they may be damaged.
  49. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 5

  50. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 3

  51. ADD HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 3

  52. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 
  53. WARM UP COMPRESSOR 
  54. INSPECT HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 2

  55. INSPECT SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 2

  56. ADJUST SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 3

  57. INSPECT FOR ENGINE OIL LEAK 

    Refer to PROCEDURE - Step 6

  58. INSPECT COOLANT LEAK (for Inverter) 

    Refer to PROCEDURE - Step 1

  59. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 4

  60. INSPECT FOR REFRIGERANT LEAK 
  61. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  62. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 7

  63. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1

  64. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK 

    Refer to PROCEDURE - Step 2

  65. INSTALL REAR ENGINE UNDER COVER LH 
    1. Install the rear engine under cover LH to the vehicle with the 6 clips.
  66. INSTALL REAR ENGINE UNDER COVER RH 
    1. Install the rear engine under cover RH to the vehicle with the 6 clips.
  67. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY 
    1. Install the No. 1 engine under cover assembly to the vehicle with the 4 bolts, 4 screws and 4 clips.

      Bolt 

      Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

      GTY801884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
  68. INSTALL FRONT WHEELS 

    Refer to PROCEDURE - Step 1

  69. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  70. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [07/2022 - ]

  71. PERFORM INITIALIZATION 

    Refer to PROCEDURE - Step 8

  72. INSPECT IGNITION TIMING 

    Refer to PROCEDURE - Step 7

  73. INSPECT ENGINE IDLE SPEED 

    Refer to PROCEDURE - Step 8

  74. INSPECT CO/HC 

    Refer to PROCEDURE - Step 10

  75. CHECK SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [10/2018 - ]

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