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Installation [11/2016 - ]: Procedure

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  1. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Temporarily install the front engine mounting insulator with the 3 nuts.
  2. TEMPORARILY 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 with the 3 nuts.
  3. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH 

    HINT: 

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

    1. Temporarily install the engine mounting insulator RH with the 3 nuts.
  4. TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Temporarily install the rear engine mounting insulator with the 2 nuts.
  5. INSTALL ENGINE HANGERS 

    See step  63

  6. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND 
    1. Remove the engine assembly from the engine stand.
  7. 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 lifter, secure the engine assembly before servicing.
    2. Install the flywheel sub-assembly.

      See step  2

  8. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY 

    See step  3

  9. 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 3

  10. INSTALL NO. 3 AUTOMATIC TRANSMISSION CASE COVER 

    Refer to PROCEDURE - Step 8

  11. INSTALL MOTOR CABLE BRACKET 

    Refer to PROCEDURE - Step 13

  12. INSTALL FRONT FRAME ASSEMBLY 
    1. Install the rear engine mounting insulator with the 3 bolts.

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

    2. Install the engine mounting insulator RH with the nut.

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

    3. Install the engine mounting insulator LH with the nut.

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

    4. Install the HV transaxle mass damper with the bolt.

      Torque: 13.5 N*m (138 kgf*cm, 10 ft.*lbf) 

    5. Install the front engine mounting insulator with the bolt.

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

    6. Fully tighten the 11 temporarily installed nuts of the engine mounting insulators.
      GTY726004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Engine Mounting Insulator *2 Engine Mounting Insulator RH
      *3 Engine Mounting Insulator LH *4 Rear Engine Mounting Insulator

      Nut (A) 

      Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf) 

      Nut (B) 

      Torque: 99 N*m (1010 kgf*cm, 73 ft.*lbf) 

      HINT: 

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

    7. Install the 7 hole plugs to the front frame assembly.

      HINT: 

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

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

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 3

  16. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 4

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

    Refer to PROCEDURE - Step 8

  18. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 9

  19. INSTALL NO. 2 EGR PIPE GASKET 

    Refer to PROCEDURE - Step 1

  20. INSTALL EGR INLET GASKET 

    Refer to PROCEDURE - Step 2

  21. INSTALL EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 3

  22. CONNECT NO. 6 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 4

  23. CONNECT WATER BY-PASS HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 5

  24. CONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 6

  25. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    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. Install the engine assembly with transaxle to the vehicle.
      NOTE:
      • Do not raise the engine assembly with transaxle more than necessary. If the engine assembly with transaxle is raised excessively, the vehicle may also be lifted up.
      • 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 RH and frame side rail plate LH to the front frame assembly and vehicle body with the 6 bolts and 2 nuts.

      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) 

      GTY433426Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    7. Install the front suspension member rear brace RH and front suspension member rear brace 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) 

      HINT: 

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

      Refer to INITIALIZATION [11/2016 - ]

  26. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover with the 2 bolts.

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

  27. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET 
    1. Install the No. 1 exhaust pipe support bracket with the 2 bolts.

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

  28. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Connect the transmission control cable assembly to the No. 2 transmission control cable bracket and 2 No. 3 transmission control cable brackets.
    2. Install a new clip to the No. 1 transmission control cable bracket.
    3. Connect the transmission control cable assembly to the No. 1 transmission control cable bracket.
      GTY432378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw A
      *b Claw B
      *c Transmission Control Cable Assembly
      NOTE:
      • Make sure that the claws A on the clip are securely fit into the No. 1 transmission control cable bracket holes.
      • Make sure that the transmission control cable assembly is securely engaged to the claws B of the clip.
    4. Connect the transmission control cable assembly to the transmission control shaft lever with the nut.

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

      NOTE:

      Before connecting the transmission control cable assembly, check that the shift lever position sensor and the shift lever are in neutral.

  29. INSTALL FRONT DRIVE SHAFT ASSEMBLY 

    Refer to INSTALLATION [02/2014 - ]

  30. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 10

  31. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 7

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

    Refer to PROCEDURE - Step 19

  33. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube sub-assembly (for Port Injection).
      1. Connect the fuel tube sub-assembly to the fuel pipe.

        Refer to PRECAUTION [11/2016 - ]

    2. Connect the fuel tube sub-assembly (for Direct Injection).
      1. Connect the fuel tube sub-assembly to the fuel pipe.

        Refer to PRECAUTION [11/2016 - ]

    3. Install the fuel pipe clamp to the fuel tube connector.
    4. Install the No. 2 fuel pipe clamp to the fuel pipe clamp.
  34. CONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  35. CONNECT DISCHARGE HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  36. CONNECT ENGINE WIRE 
    1. Connect the No. 3 earth wire with the bolt.

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

    2. Connect the engine wire with the bolt.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

    3. Engage the 5 clamps.
    4. Engage the claw to connect the engine wire to the engine room relay block assembly.
    5. Connect the 3 connectors.
  37. INSTALL ECM 

    Refer to INSTALLATION [11/2016 - ]

  38. INSTALL ENGINE MOVING CONTROL ROD 

    HINT: 

    Perform this procedure only when replacement of the engine moving control rod or No. 3 engine mounting stay RH is necessary.

    1. Temporarily install the No. 3 engine mounting stay RH and engine moving control rod to the engine moving control rod bracket with the 2 bolts.
      GTY695559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Engine Moving Control Rod
      *2 No. 3 Engine Mounting Stay RH
      *3 Engine Moving Control Rod Bracket
    2. Tighten the bolt (A).

      Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf) 

  39. INSTALL ENGINE MOVING CONTROL ROD BRACKET 
    1. When replacing the engine moving control rod or No. 3 engine mounting stay RH.
      GTY700010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

        Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

        NOTE:

        Temporarily tighten the bolt (A), (B), (C) and (D), and then fully tighten the 4 bolts in the order of (A), (B), (C) and (D).

      2. Using SST and a 14 mm union nut wrench, tighten the bolt.
        GTY724924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Union Nut Wrench
        *b Fulcrum Length of 25 mm (0.984 in.)
        *c Fulcrum Length of 150 mm (5.91 in.)
        *d Fulcrum Length of 255 mm (10.0 in.)
        • SST: 09961-00950 

        Torque

        Specified tightening torque 

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

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [11/2016 - ]

        • When using a 14 mm union nut wrench (fulcrum length of 25 mm (0.984 in.)) + SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 255 mm (10.0 in.)): 30.8 N*m (314 kgf*cm, 23 ft.*lbf)
    2. When not replacing the engine moving control rod or No. 3 engine mounting stay RH.
      GTY733881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

        Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

        NOTE:

        Temporarily tighten the bolt (A), (B), (C) and (D), and then fully tighten the 4 bolts in the order of (A), (B), (C) and (D).

  40. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for Engine Mounting Stay Side) 
    1. Install the No. 2 engine mounting stay RH with the bolt.

      Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

    2. Install the 2 nuts.

      Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 

  41. INSTALL RESERVOIR BRACKET 
    1. Install the reservoir bracket with the 2 nuts.

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

  42. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Install the brake master cylinder reservoir assembly with the 2 nuts.

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

    2. Engage the clamp to connect the wire harness to the brake master cylinder reservoir assembly.
  43. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY 
    1. Connect the fuel vapor feed hose assembly to the purge valve (purge VSV) and slide the clip to secure it.
  44. CONNECT HEATER WATER HOSE 
    1. Connect the heater water hose to the water inlet pipe and slide the clip to secure it.
  45. CONNECT WATER HOSE SUB-ASSEMBLY 
    1. Install the water hose sub-assembly to the clamp.
    2. Connect the water hose sub-assembly to the water outlet and slide the clip to secure it.
  46. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.
  47. 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.
  48. CONNECT NO. 3 MOTOR COOLING HOSE 
    1. Connect the No. 3 motor cooling hose to the outlet oil cooler tube sub-assembly and slide the clip to secure it.
  49. CONNECT NO. 1 MOTOR COOLING HOSE 
    1. Connect the No. 1 motor cooling hose to the inlet oil cooler tube sub-assembly and slide the clip to secure it.
  50. INSTALL INVERTER TRAY BRACKET SUB-ASSEMBLY 
    1. Install the inverter tray bracket sub-assembly with the 5 bolts.
      GTY452601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

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

    2. Engage the 2 clamps to connect the water by-pass hose.
  51. INSTALL INVERTER WITH CONVERTER ASSEMBLY 

    Refer to INSTALLATION [11/2016 - ]

  52. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION [02/2014 - ]

  53. INSTALL FRONT WHEELS 

    Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 

  54. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 4

  55. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 3

  56. ADD HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 2

  57. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  58. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  59. WARM UP COMPRESSOR 

    Refer to PROCEDURE - Step 3

  60. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 4

  61. INSPECT ENGINE OIL LEVEL 

    Refer to ON-VEHICLE INSPECTION [11/2016 - ]

  62. INSPECT HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 1

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

    Refer to PROCEDURE - Step 2

  64. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  65. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1

  66. INSPECT FOR OIL LEAK 
  67. INSPECT FOR EXHAUST GAS LEAK 
  68. INSPECT IGNITION TIMING 

    See step  8

  69. INSPECT ENGINE IDLE SPEED 

    See step  9

  70. INSPECT CO/HC 

    See step  11

  71. INSPECT SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 1

  72. ADJUST SHIFT LEVER POSITION 

    Refer to ADJUSTMENT [02/2014 - ]

  73. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [11/2016 - ]

  74. 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.
      GTY723631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 4

  76. INSTALL RADIATOR SIDE SEAL RH 

    Refer to PROCEDURE - Step 5

  77. INSTALL RADIATOR SIDE DEFLECTOR SEAL LH 

    Refer to PROCEDURE - Step 6

  78. INSTALL FRONT FENDER APRON SEAL LH 
    1. Install the front fender apron seal LH with the 2 bolts and clip.
  79. INSTALL FRONT FENDER APRON SEAL RH 
    1. Install the front fender apron seal RH with the 2 bolts and clip.
  80. INSTALL FRONT FENDER LINER LH 
    1. Install the front fender liner LH with the 3 screws and 3 clips.
  81. INSTALL FRONT FENDER LINER RH 
    1. Install the front fender liner RH with the 3 screws and 3 clips.
  82. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 26

  83. INSTALL NO. 2 ENGINE UNDER COVER 
    1. Install the No. 2 engine under cover with the 2 bolts, 2 screws and clip.
  84. INSTALL NO. 1 ENGINE UNDER COVER 
    1. Install the No. 1 engine under cover with the 8 bolts, 6 screws and 3 clips.
  85. CHECK FOR SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [11/2016 - ]

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