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Engine Assembly: Installation

  1. INSTALL KNOCK CONTROL SENSOR  (See INSTALLATION )
  2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Apply adhesive to 2 or 3 threads of the oil pressure switch.

      Adhesive: 

      Part No.08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent. 

      Fig 1: Applying Adhesive On Threads Of Oil Pressure Switch
      G04974196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a deep socket wrench 24 mm, install the oil pressure switch.
      Fig 2: Installing Oil Pressure Switch
      G05200506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

  3. INSTALL THERMOSTAT  (See INSTALLATION )
  4. INSTALL WATER INLET  (See INSTALLATION )
  5. INSTALL WATER INLET PIPE  (See INSTALLATION )
  6. INSTALL INTAKE AIR CONNECTOR BRACKET NO.2 
    1. Install the intake air connector bracket No.2 with the 2 bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.
      Fig 3: Locating Intake Air Connector Bracket And Bolts
      G05200507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

  7. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 
    1. Temporarily install the mounting bracket with the 4 bolts.
    2. Install the mounting bracket by tightening the 4 bolts in the order shown in the illustration.
      Fig 4: Locating Mounting Bracket And Bolts
      G05200508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL ENGINE MOUNTING STAY BRACKET 
    1. Install the 3 bolts, nut and engine mounting stay bracket.

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

      Fig 5: Locating Engine Mounting Stay Bracket, Bolts And Nuts
      G05200501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL ENGINE MOUNTING BRACKET RH 
    1. Install the 3 bolts and engine mounting bracket RH.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

      Fig 6: Locating Engine Mounting Bracket RH, Bolts And Nuts
      G05200500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL ENGINE MOUNTING BRACKET REAR 
    1. Install the 3 bolts and engine mounting bracket rear.
      Fig 7: Locating Engine Mounting Bracket Rear, Bolts And Nuts
      G05200499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

  11. INSTALL MANIFOLD STAY NO.2 
    1. Install the 3 bolts and engine mounting bracket rear.

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

  12. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2 (See  INSTALLATION   ) 
  13. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See  INSTALLATION   ) 
  14. INSTALL MANIFOLD CONVERTER INSULATOR NO.3 (See  INSTALLATION   ) 
  15. INSTALL IGNITION COIL ASSEMBLY 

    Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf) 

  16. INSTALL WATER OUTLET (See  INSTALLATION   ) 
  17. INSTALL INTAKE MANIFOLD (See  INSTALLATION   ) 
  18. INSTALL INTAKE AIR SURGE TANK  (See INSTALLATION )
  19. INSTALL EMISSION CONTROL VALVE SET  (See INSTALLATION )
  20. INSTALL ENGINE HANGER NO.2 
    1. Install the No.2 engine hanger in the correct direction shown in the illustration.
      Fig 8: Identifying Engine Hanger
      G05200493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 20 N*m (200 kgf*cm, 15 ft.*lbf) 

  21. REMOVE ENGINE STAND 
  22. INSTALL FLYWHEEL SUB-ASSEMBLY (See  INSTALLATION   ) 
  23. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY (See  INSTALLATION   ) 
  24. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY  (See INSTALLATION )
  25. INSTALL ENGINE MOUNTING BRACKET FRONT  (See INSTALLATION )
  26. INSTALL FLYWHEEL HOUSING UNDER COVER  (See INSTALLATION )
  27. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
  28. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH  (See INSTALLATION )
  29. INSTALL FRONT FRAME ASSEMBLY 
    1. Install the engine mounting insulators RH and LH with the 2 nuts.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

      Fig 9: Locating Engine Mounting Insulator RH And LH With Nuts
      G05129362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine mounting insulator FR with the nut.

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

      Fig 10: Locating Engine Mounting Insulator FR With Nut
      G05200496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the engine mounting insulator RR with the 2 bolts.

      Torque: 75 N*m (765 kgf*cm, 55 ft.*lbf) 

      Fig 11: Locating Engine Mounting Insulator RR And Bolts
      G05200497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL HV TRANSAXLE MASS DAMPER 
    1. Install the bolt and transaxle mass damper.
      Fig 12: Locating Transaxle Mass Damper And Bolts
      G05200494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 14 N*m (138 kgf*cm, 10 ft.*lbf) 

  31. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (See  INSTALLATION   ) 
  32. INSTALL MANIFOLD STAY (See  INSTALLATION   ) 
  33. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See  INSTALLATION   ) 
  34. INSTALL ENGINE WIRE 
  35. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on the engine lifter.
    2. Install the engine assembly to the vehicle.
    3. Install the frame side rail plates RH and LH with the 6 bolts and 2 nuts.
      Fig 13: Locating Frame Side Rail Plate RH And LH
      G05200517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Bolt A 

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

      Bolt B 

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

      Nut C 

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

    4. Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.
      Fig 14: Locating Front Suspension Member Brace Rear RH And LH
      G05200518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Bolt A 

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

      Bolt B 

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

      Nut C 

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

  36. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY  (See INSTALLATION )
  37. INSTALL FRONT AXLE ASSEMBLY LH 
    1. Install the drive shaft assembly LH to the front axle assembly LH.
      NOTE:
      • Be careful not to damage the outboard joint boot.
      • Be careful not to damage the speed sensor rotor.
  38. INSTALL FRONT AXLE ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  39. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH  (See INSTALLATION )
  40. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  41. INSTALL TIE ROD END SUB-ASSEMBLY LH  (See INSTALLATION )
  42. INSTALL TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  43. INSTALL SPEED SENSOR FRONT LH  (See INSTALLATION )
  44. INSTALL SPEED SENSOR FRONT RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  45. INSTALL FRONT AXLE SHAFT LH NUT  (See INSTALLATION )
  46. INSTALL FRONT AXLE SHAFT RH NUT 

    HINT:

    Perform the same procedure as above on the opposite side.

  47. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  (See INSTALLATION )
  48. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  49. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.3 
    1. Using vernier calipers, measure the free length of the compression spring.

      Minimum length: 

      41.5 mm (1.634 in.) 

      HINT:

      If the free length is less than the minimum, replace the compression spring.

      Fig 15: Measuring Free Length Of Compression Spring
      G05239315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket to the exhaust pipe front No. 3 as shown in the illustration.
      Fig 16: Identifying Gasket To Exhaust Pipe Front
      G05200520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.
      Fig 17: Locating Gaskets And Exhaust Pipe, Bolts And Nuts
      G05200490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: Bolt 

      48 N*m (490 kgf*cm, 35 ft.*lbf) 

      Nut 

      56 N*m (571 kgf*cm, 41 ft.*lbf) 

    4. Connect the heated oxygen sensor connector.
  50. INSTALL EXHAUST PIPE ASSEMBLY FRONT 
    1. Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.
      Fig 18: Locating Gaskets And Exhaust Pipe, Bolts And Nuts
      G05200489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) 

    2. Connect the heated oxygen sensor connector.
  51. CONNECT WIRE HARNESS 
    1. Connect the power steering link connector and clamp.
    2. Install the ground cable.
  52. CONNECT ENGINE WIRE 
    1. Install the 2 nuts and pull in the engine wire harness.

      Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) 

    2. Connect the engine wire harness to the ECM and the junction block.
    3. Install the body ground and connector.
  53. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY  (See INSTALLATION )
  54. CONNECT WATER HOSE 
  55. INSTALL HEATER WATER PUMP ASSEMBLY 
    1. Install the bolt and heater water pump assembly.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

      Fig 19: Locating Bolt And Heater Water Pump Assembly
      G05200488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. CONNECT OIL COOLER INLET TUBE SUB-ASSEMBLY (VW OIL COOLER) 
    1. Using pliers, grip the claws of the clip and slide the clip to connect the oil cooler inlet tube.
      Fig 20: Locating Oil Cooler Inlet Tube Sub-Assembly (W/ Oil Cooler)
      G05200487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. CONNECT OIL COOLER OUTLET TUBE SUB-ASSEMBLY (W/ OIL COOLER) 

    HINT:

    Connection of the oil cooler outlet tube is the same as for the oil cooler inlet tube.

  58. CONNECT RADIATOR HOSE INLET 
  59. CONNECT RADIATOR HOSE OUTLET 
  60. CONNECT HEATER WATER INLET HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to connect the heater water inlet hose.
  61. CONNECT HEATER WATER OUTLET HOSE 

    HINT:

    Connection of the heater water outlet hose is the same as for the heater water inlet hose.

    Fig 21: Locating Heater Water Outlet Hose
    G05200486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. CONNECT FUEL PIPE SUB-ASSEMBLY NO.1 
    1. Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel tube sub-assembly to the fuel delivery pipe.
    2. Install the EFI fuel pipe clamp.
      Fig 22: Aligning Connector With Pipe
      G05200526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Install the control cable to the transaxle with the bolt.

      Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) 

      Fig 23: Locating Control Cable To Transaxle With Bolt
      G05200483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the control shaft lever with the nut.

      Torque: 6.9 N*m (70 kgf*cm, 61 ft.*lbf) 

    3. Install the control cable and a new clip to the bracket.
      Fig 24: Locating Control Cable And New Clip To Bracket
      G05200482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSTALL INVERTER BRACKET NO.1 
    1. Install the 4 bolts and inverter bracket.
      Fig 25: Locating Bolts And Inverter Bracket
      G05200481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Install the harness clamp and hose clamp.
  65. INSTALL COMPRESSOR W/ MOTOR ASSEMBLY 
    1. Temporarily install the compressor and magnetic clutch with the 3 bolts.
      Fig 26: Locating Compressor And Magnetic Clutch
      G05200530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the compressor and magnetic clutch by tightening the 3 bolts in the order shown in the illustration.

      Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

    3. Connect the 2 connectors.
  66. INSTALL ENGINE MOUNTING STAY NO.2 RH (See  INSTALLATION   ) 
  67. INSTALL ENGINE MOVING CONTROL ROD (See  INSTALLATION   ) 
  68. INSTALL AIR CLEANER BRACKET 
    1. Install the 2 bolts and air cleaner bracket.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

      Fig 27: Locating Bolts And Air Cleaner Bracket
      G05200479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. INSTALL RESERVOIR BRACKET 
    1. Install the 2 bolts, nut and reservoir bracket.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

    2. Connect the clamp.
      Fig 28: Locating Reservoir Bracket
      G05200478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY 
    1. Install the 2 bolts and brake master cylinder reservoir to the bracket.
      Fig 29: Locating Bolts And Brake Master Cylinder Reservoir To Bracket
      G05200477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

    2. Connect the connector.
  71. INSTALL W/ CONVERTER INVERTER ASSEMBLY  (See INSTALLATION )
  72. INSTALL INVERTER BRACKET NO.4  (See INSTALLATION )
  73. INSTALL ENGINE ROOM RELAY BLOCK ASSEMBLY  (See INSTALLATION )
  74. REMOVE INVERTER COVER  (See INSTALLATION )
  75. CONNECT NO.3 WIRE FRAME  (See INSTALLATION )
  76. CONNECT MG ECU CONNECTOR  (See INSTALLATION )
  77. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR  (See INSTALLATION )
  78. CONNECT ENGINE WIRE NO.4  (See INSTALLATION )
  79. CHECK HIGH VOLTAGE CABLE CONNECTION  (See INSTALLATION )
  80. INSTALL INVERTER COVER  (See INSTALLATION )
  81. INSTALL POWER STEERING ECU BRACKET  (See INSTALLATION )
  82. CONNECT WATER HOSE  (See INSTALLATION )
  83. INSTALL INVERTER RESERVE TANK SUB-ASSEMBLY  (See INSTALLATION )
  84. CONNECT ENGINE ROOM WIRE NO.2  (See INSTALLATION )
  85. CONNECT CIRCUIT BREAKER SENSOR NO.1  (See INSTALLATION )
  86. INSTALL POWER STEERING ECU ASSEMBLY  (See INSTALLATION )
  87. INSTALL INVERTER BRACKET NO.5  (See INSTALLATION )
  88. INSTALL AIR CLEANER CASE W/ RESONATOR  (See INSTALLATION )
  89. INSTALL AIR CLEANER CAP W/INLET 
    1. Install the air cleaner filter element to the air cleaner case.
    2. Install the 2 bolts, 4 clamps and air cleaner cap w/ inlet.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

      Fig 30: Locating Air Cleaner Cap W/Inlet And Clamps And Bolts
      G05200225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. INSTALL BATTERY CARRIER SUB-ASSEMBLY 
    1. Install the 5 bolts and battery carrier.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

  91. INSTALL BATTERY 
    1. Install the battery clamp and battery.
      Fig 31: Locating Battery Carrier, Bolts And Nuts
      G05200475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  92. INSTALL SERVICE PLUG GRIP  (See INSTALLATION )
  93. INSTALL FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER 
    1. Remove the 4 shock absorber nuts.
    2. Install the 4 nuts and front suspension brace sub-assembly upper center.
      Fig 32: Locating Front Suspension Brace Sub-Assembly Upper Center
      G05200474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 80 N*m (815 kgf*cm, 59 ft.*lbf) 

  94. INSTALL FRONT WHEELS 

    Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 

  95. ADD AND INSPECT HYBRID TRANSAXLE FLUID (w/o Oil Cooler)  (See HYBRID TRANSAXLE FLUID )
  96. ADD AND INSPECT HYBRID TRANSAXLE FLUID (w/ Oil Cooler)  (See HYBRID TRANSAXLE FLUID )
  97. ADD ENGINE OIL 
  98. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  99. ADD COOLANT (Hybrid side)  (See COOLANT )
  100. ADD COOLANT (Engine side)  (See COOLANT )
  101. INSPECT FOR OIL LEAK 
  102. INSPECT FOR ENGINE COOLANT LEAK (Hybrid side) 
  103. INSPECT FOR ENGINE COOLANT LEAK (Engine side)  (See COOLING SYSTEM )
  104. INSPECT FOR EXHAUST GAS LEAK 
  105. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    (See FRONT WHEEL ALIGNMENT )

  106. INSTALL ENGINE UNDER COVER NO.2 
    1. Install the 2 bolts and engine under cover No.2.
  107. INSTALL FRONT FENDER APRON SEAL LH 
    1. Install the 2 bolts, clip and fender apron seal LH.
      Fig 33: Locating Clip And Fender Apron Seal LH
      G05200473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  108. INSTALL FRONT FENDER APRON SEAL RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  109. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH 
    1. Install the fender splash shield with the screw and clip.
      Fig 34: Locating Fender Splash Shield With Screw And Clip
      G05200472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  110. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  111. INSTALL ENGINE UNDER COVER NO.1 
    1. Install the 6 bolts, 2 screws, 2 clips and engine under cover.
      Fig 35: Locating Engine Under Cover And Bolts, Screws And Clips
      G05200471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  112. INSPECT STEERING WHEEL CENTER POINT 
  113. INSPECT IGNITION TIMING (See  ON-VEHICLE INSPECTION   ) 
  114. INSPECT ENGINE IDLE SPEED (See  ON-VEHICLE INSPECTION   ) 
  115. INSPECT CO/HC (See  ON-VEHICLE INSPECTION   ) 
  116. CHECK ABS SPEED SENSOR SIGNAL 

    (See TEST MODE PROCEDURE )

  117. PERFORM INITIALIZATION 
    1. Some system need initialization when reconnecting the cable from the battery terminal. (See INITIALIZATION )
  118. INSTALL ENGINE ROOM SIDE LH COVER NO.2 
    1. Fit the clips and install the engine room side LH cover.
      Fig 36: Identifying Engine Room Side LH Cover
      G05200470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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