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Installation [10/2014 - ]: Procedure

  1. REMOVE ENGINE STAND 
    1. Using an engine sling device and engine lift, secure the engine assembly.
      NOTE:
      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hanger from deforming or becoming damaged.
      • 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 or removed from an engine stand.
    2. Remove the engine stand from the engine assembly.
  2. INSTALL FLYWHEEL SUB-ASSEMBLY 

    See step  2

  3. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY 

    See step  3

  4. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 10

  5. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  6. INSTALL DRIVE SHAFT BEARING BRACKET 
    1. Install the drive shaft bearing bracket with the 3 bolts.

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

  7. INSTALL ENGINE MOUNTING BRACKET RH 
    1. Install the engine mounting bracket RH with the 3 bolts.

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

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

      HINT: 

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

  9. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH 
    1. Temporarily install the engine mounting insulator LH with the 3 nuts.

      HINT: 

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

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

      HINT: 

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

  11. INSTALL FRONT FRAME ASSEMBLY 
    1. Install the engine mounting insulator LH with the nut.

      Torque: 95 N*m (969 kgf*cm, 70 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 front engine mounting insulator with the bolt.

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

    4. Fully tighten the 9 temporarily installed nuts of the engine mounting insulators to the specified torque.
      GTY606979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Front Engine Mounting Insulator *b Engine Mounting Insulator RH
      *c Engine Mounting Insulator LH - -

      Nut A 

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

      Nut B 

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

      HINT: 

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

    5. Install the 4 hole plugs.
      GTY551463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Engine Mounting Insulator RH *b Engine Mounting Insulator LH

      HINT: 

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

    6. Install the wire harness clamp bracket to the front frame assembly with the bolt.

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

    7. Engage the 2 clamps to connect the No. 4 engine wire from the front engine mounting insulator.
  12. INSTALL ENGINE WIRE 
    1. Install the engine wire to the engine assembly.
  13. CONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 12

  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on an engine lifter.
      NOTE:
      • Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
      • Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly.
      • To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle.
      • Make sure to support the engine assembly with transaxle securely to prevent it from falling.
      • To prevent coolant leaks, do not position the height adjustment attachments or plate lift attachments under the No. 2 motor water jacket cover assembly.
        GTY587654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *1 No. 2 Motor Water Jacket Cover Assembly
    2. Remove the engine hangers (See step  1).
    3. Install the engine assembly with transaxle to the vehicle.
      NOTE:

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

      HINT: 

      • Make sure that the engine 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.
    4. Install the frame side rail plate RH and LH with the 4 bolts and 2 nuts.
      GTY559182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      A 

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

      B 

      Torque: 32 N*m (329 kgf*cm, 24 ft.*lbf) 

    5. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.

      C 

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

      D 

      Torque: 32 N*m (329 kgf*cm, 24 ft.*lbf) 

      HINT: 

      Perform "Inspection After Repair" after replacing the engine assembly (Refer to INITIALIZATION [10/2014 - ] ).

  15. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover.
  16. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH 

    Refer to PROCEDURE - Step 12

  17. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 1

  18. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH 

    Refer to PROCEDURE - Step 2

  19. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  20. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  21. CONNECT TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 9

  22. CONNECT TIE ROD ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  23. INSTALL FRONT SPEED SENSOR LH 

    Refer to PROCEDURE - Step 19

  24. INSTALL FRONT SPEED SENSOR RH 

    HINT: 

    Use the same procedure described for the LH side.

  25. INSTALL FRONT STABILIZER LINK ASSEMBLY LH 

    Refer to PROCEDURE - Step 9 . Refer to PROCEDURE - Step 13

  26. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  27. INSTALL FRONT AXLE SHAFT NUT LH 

    Refer to PROCEDURE - Step 7

  28. INSTALL FRONT AXLE SHAFT NUT RH 

    HINT: 

    Use the same procedure described for the LH side.

  29. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 11

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

    Refer to PROCEDURE - Step 9

  31. CONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  32. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 4

  33. INSTALL ENGINE MOVING CONTROL ROD 
    1. Temporarily install the engine moving control rod and No. 3 engine mounting stay RH to the engine moving control rod bracket with the bolt.

      HINT: 

      Perform this procedure only when replacement of the engine moving control rod is necessary.

  34. INSTALL ENGINE MOVING CONTROL ROD BRACKET 
    1. When the engine moving control rod has been replaced.
      1. Temporarily install the engine moving control rod bracket with the 4 bolts.
        GTY541123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Fully tighten the bolts except the bolt A.
        GTY578414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      3. Using SST, fully tighten the bolt A.
        GTY317955Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        • SST: 09961-00950 

        without SST 

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

        with SST 

        Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 

        NOTE:
        • The "with SST" torque value is effective when using SST with a fulcrum length of 150 mm (5.91 in.) and a torque wrench with a fulcrum length of 260 mm (10.2 in.) (Refer to PRECAUTION [10/2014 - ] ).
        • The "with SST" torque value is effective when SST is parallel to the torque wrench.
    2. When the engine moving control rod has been reused.
      GTY541123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the engine moving control rod bracket with the 4 bolts.
      2. Fully tighten the 4 bolts.

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

  35. INSTALL EARTH WIRE 
    1. Install the earth wire to the engine moving control rod bracket with the bolt.

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

  36. INSTALL NO. 2 ENGINE MOUNTING STAY RH 
    1. Install the No. 2 engine mounting stay RH with the 2 bolts.

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

  37. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  38. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose, and slide the clip to secure it.
  39. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose, and slide the clip to secure it.
  40. CONNECT NO. 5 INVERTER COOLING HOSE 
    1. Connect the No. 5 inverter cooling hose to the hybrid vehicle transaxle assembly, and slide the clip to secure it.
  41. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose, and slide the clip to secure it.
    2. Connect the air fuel ratio sensor wire to the No. 1 radiator hose with the hose clamp.
  42. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose, and slide the clip to secure it.
  43. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Connect the transmission control cable assembly to the 2 transmission control cable brackets.
    2. Install a new clip to the No. 1 transmission control cable bracket.
    3. Install the transmission control cable assembly to the No. 1 transmission control cable bracket.
      GTY591411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Transmission Control Cable Assembly
      *2 No. 1 Transmission Control Cable Bracket
      *a Claw A
      *b Claw B
      NOTE:
      • Make sure that the claws A on the clip are securely fit into the bracket holes.
      • Make sure that the cable is securely installed inside of the claws B of the clip.
    4. Connect the transmission control cable assembly to the control shaft lever with the nut.

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

  44. CONNECT ENGINE WIRE 
    1. Connect the wire harness clamp.
      GTY315313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the connector to the ECM with the lock lever.
    3. Install the wire harness and wire harness bracket with the 2 bolts.

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

    4. Engage the wire harness clamp to connect the engine wire to the engine room relay block.
    5. Connect the 4 connectors.
    6. Install the No. 1 relay block cover.
  45. INSTALL NO. 4 ENGINE WIRE 
    1. Engage the 2 wire harness clamps to connect the No. 4 engine wire to the fan shroud.
  46. INSTALL INVERTER WITH CONVERTER ASSEMBLY 

    Refer to PROCEDURE - Step 12

  47. CONNECT NO. 1 INVERTER COOLING HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 13

  48. CONNECT NO. 4 INVERTER COOLING HOSE 

    Refer to PROCEDURE - Step 14

  49. CONNECT NO. 3 ENGINE ROOM WIRE 

    Refer to PROCEDURE - Step 15

  50. CONNECT LOW VOLTAGE CONNECTOR 

    Refer to PROCEDURE - Step 16

  51. REMOVE CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 19

  52. CONNECT NO. 4 FLOOR WIRE 

    Refer to PROCEDURE - Step 18

  53. CONNECT NO. 4 ENGINE WIRE 

    Refer to PROCEDURE - Step 19

  54. INSTALL CONNECTOR COVER ASSEMBLY 

    Refer to PROCEDURE - Step 20

  55. INSTALL NO. 3 MOTOR CABLE BRACKET 

    Refer to PROCEDURE - Step 21

  56. CONNECT MOTOR CABLE 

    Refer to PROCEDURE - Step 22

  57. INSTALL UPPER INVERTER COVER 

    Refer to PROCEDURE - Step 23

  58. CONNECT GENERATOR CABLE 

    Refer to PROCEDURE - Step 24

  59. INSTALL UPPER INVERTER COVER 

    Refer to PROCEDURE - Step 25

  60. INSTALL NO. 4 INVERTER BRACKET 

    Refer to PROCEDURE - Step 26

  61. INSTALL NO. 5 INVERTER BRACKET 

    Refer to PROCEDURE - Step 27

  62. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Insert the projection of the air cleaner case sub-assembly into the hole of the No. 2 air cleaner bracket as shown in the illustration.
      GTY605670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Projection
    2. Install the 2 bolts.

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

  63. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
    1. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.
      NOTE:

      Install the air cleaner filter element sub-assembly with the printed side facing the vehicle left.

  64. INSTALL AIR CLEANER CAP SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  65. INSTALL INLET AIR CLEANER ASSEMBLY 
    1. Install the inlet air cleaner assembly with the 2 bolts.

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

  66. INSTALL SERVICE PLUG GRIP 

    (Refer to INSTALLATION [10/2014 - ] )

  67. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 4

  68. ADD HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 2

  69. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 2

  70. ADD COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  71. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  72. WARM UP COMPRESSOR 

    Refer to PROCEDURE - Step 3

  73. WARM UP ENGINE 
  74. INSPECT HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 1

  75. INSPECT ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1

  76. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  77. INSPECT FOR OIL LEAK 
  78. INSPECT FOR COOLANT LEAK (for Inverter) 

    Refer to PROCEDURE - Step 1

  79. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1

  80. INSPECT FOR EXHAUST GAS LEAK 
  81. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 4

  82. INSPECT IGNITION TIMING 

    See step  7

  83. INSPECT ENGINE IDLE SPEED 

    See step  8

  84. INSPECT CO/HC 

    See step  10

  85. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Engage the 3 pins to install the No. 1 engine cover sub-assembly.
  86. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 3 Refer to PROCEDURE - Step 3

  87. INSPECT AND ADJUST SHIFT LEVER POSITION 

    (Refer to ADJUSTMENT [10/2014 - ] )

  88. INSTALL FRONT FENDER APRON SEAL LH 
  89. INSTALL FRONT FENDER APRON SEAL RH 
  90. INSTALL ENGINE UNDER COVER LH 
  91. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 
  92. INSTALL ENGINE UNDER COVER RH 
  93. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 
  94. INSTALL FRONT WHEEL 

    Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 

  95. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    (Refer to ADJUSTMENT [10/2014 - 10/2015] or ADJUSTMENT [10/2015 - ] )

  96. CHECK FOR SPEED SENSOR SIGNAL 

    (Refer to TEST MODE PROCEDURE [10/2014 - 10/2015] or TEST MODE PROCEDURE [10/2015 - ] )

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