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Installation [11/2015 - 06/2017]: Procedure

  1. INSTALL NO. 1 ENGINE HANGER 

    See step  40

  2. CONNECT ENGINE WIRE 
    1. Connect all of the clamps and connectors and install the engine wire from the engine assembly.
  3. REMOVE ENGINE STAND 
    1. Using a chain block and sling device, secure the engine assembly.
      NOTE:
      • Make sure that the sling angle is correct to prevent the engine assembly and engine hangers from being damaged or deformed.
      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
    2. Remove the engine stand from the engine assembly.
  4. 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 5 bolts.
    2. Tighten the 5 bolts in the order shown in the illustration.
      Fig 1: LH Engine Mount Bolts Tightening Sequence
      GTY730723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Connect the wire harness clamp.
  5. 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 with the 3 bolts.
    2. Tighten the 3 bolts in the order shown in the illustration.
      Fig 2: RH Engine Mount Bolts Tightening Sequence
      GTY699339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  6. INSTALL FLYWHEEL SUB-ASSEMBLY 
    1. Gently place the engine assembly onto wooden blocks or equivalent.
      NOTE:
      • Set the engine assembly so that it is horizontal.
      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.
      • This step should be done while hanging the engine assembly using the sling device and chain block.
    2. Install the flywheel sub-assembly See step  2).
  7. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY 
    1. Gently place the engine assembly onto wood blocks or equivalent.
      NOTE:
      • Set the engine assembly so that it is horizontal.
      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.
      • This step should be done while hanging the engine assembly using the sling device and chain block.
    2. Install the transmission input damper assembly See step  3).
  8. INSTALL ENGINE ASSEMBLY 
    1. Make sure that the knock pins are installed to the engine assembly.
      GTY739935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Knock Pin
    2. Temporarily install the hybrid vehicle transaxle assembly to the engine assembly with the 2 bolts.

      HINT: 

      Temporarily tighten bolt B first.

    3. Fully tighten the 2 bolts in the order of A and B.

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

      Bolt Length

      45 mm (1.77 in.)

      NOTE:
      • Make sure that the wire harness or similar items are not pinched between the contact surfaces.
      • Do not forcibly pry on the hybrid vehicle transaxle.
      • Make sure to align the hybrid vehicle transaxle so that the input shaft of the hybrid vehicle transaxle will be inserted straight into the inner splines of the transmission input damper.
      • Do not apply grease either to the spline or to the input shaft.
      • When inserting the input shaft of the hybrid vehicle transaxle into the inner splines of the transmission input damper, do not shake the hybrid vehicle transaxle excessively.
      • When mounting the hybrid vehicle transaxle to the engine assembly, make sure to securely fit the knock pins into the knock holes.
      • When tightening the bolts, be sure that the mating surfaces of the engine assembly and the hybrid vehicle transaxle assembly are in close contact with one another.
    4. Install the 4 bolts.
      GTY734803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) 

      Bolt Length

      45 mm (1.77 in.)

    5. Engage the claw and install the flywheel housing side cover to the engine assembly.
    6. Install the starter hole heat insulator to the engine assembly with the 2 bolts.

      Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) 

      Bolt Length

      45 mm (1.77 in.)

    7. Install the drive shaft heat insulator bracket to the engine assembly with the 2 bolts.

      Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) 

      Bolt Length

      45 mm (1.77 in.)

    8. Connect the clamp to the drive shaft heat insulator bracket.
    9. Install the drive shaft heat insulator sub-assembly to the engine assembly and drive shaft heat insulator bracket with the bolt and nut.

      Torque: 18 N*m (179 kgf*cm, 13 ft.*lbf) 

    10. Install the 2 wire harness clamp brackets and transmission control cable clamp to the hybrid vehicle transaxle assembly with the 3 bolts.
      GTY702028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Wire Harness Clamp Bracket
      *2 Transmission Control Cable Clamp

      Bolt A 

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

      Bolt B 

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

    11. Connect the 7 clamps, 4 connectors and connect the wire harness to the hybrid vehicle transaxle assembly with the 3 bolts.
      GTY728102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

    12. Connect the 4 clamps and No. 2 engine wire.
      GTY724488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Using a sling device and chain block, set the engine assembly with transaxle on the engine lifter.
      NOTE:
      • Place the height adjustment attachment and plate lift attachment so that the engine assembly with transaxle is level.
      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.
      • Do not place any attachments onto the drain plug and rear cover plug of the hybrid vehicle transaxle assembly.
      • Make sure to support the engine assembly with transaxle securely to prevent it from falling.
    2. Remove the 2 bolts and 2 No. 1 engine hangers.
    3. Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulator sub-assembly RH and engine mounting insulator LH can be installed.
      WARNING:

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

      NOTE:

      Make sure that the engine assembly is clear of all wiring and hoses.

    4. Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the front suspension crossmember can be installed.
    5. By inserting SST into the datum holes in the front suspension crossmember RH and LH alternately, temporarily install the front suspension crossmember with the 6 bolts.
      GTY731492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Correct *b Incorrect
      *c Datum Hole - -
      • SST: 09670-00010 
    6. Connect the engine mounting insulator LH with the bolt and nut to the engine mounting bracket LH.

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

    7. Connect the engine mounting insulator sub-assembly RH with the bolt and 2 nuts to the engine assembly.

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

    8. Using several steps, uniformly tighten the 6 bolts.
      GTY739281Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt A 

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

      Bolt B 

      Torque: 151 N*m (1539 kgf*cm, 111 ft.*lbf) 

      Bolt C 

      Torque: 98 N*m (999 kgf*cm, 72 ft.*lbf) 

  10. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover.
  11. INSTALL FRONT DRIVE SHAFT ASSEMBLY 

    (Refer to INSTALLATION [11/2015 - ] )

  12. INSTALL NO. 2 ENGINE ROOM RELAY BLOCK AND NO. 2 JUNCTION BLOCK ASSEMBLY 

    See step  4

  13. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 8

  14. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  15. CONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  16. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 4

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

    Refer to PROCEDURE - Step 12

  18. CONNECT STEERING SLIDING YOKE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  19. INSTALL COLUMN HOLE COVER SILENCER SHEET 

    Refer to PROCEDURE - Step 8

  20. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 24

  21. CONNECT ENGINE WIRE 
    1. Connect the wire harness clamp.
      GTY324288Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the engine wire to the engine room main wire.
    3. Connect the engine wire to the engine room relay block and junction block assembly and engage the claw.
      GTY717560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the wire harness clamp and 2 connectors.
    5. Connect the 2 wire harness clamps.
      GTY342372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the ECM connector and lower the lever.
      NOTE:
      • When connecting the connector, make sure that dirt, water or other foreign matter does not become stuck between the connector and other part.
      • Make sure that the lever is securely locked.
  22. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  23. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY 
    1. Connect the fuel vapor feed hose assembly and slide the clip to secure it.
  24. CONNECT HEATER WATER HOSE 
    1. Connect the 2 heater water hoses to the engine assembly and slide the clips to secure them.
  25. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the engine assembly and slide the clip to secure it.
  26. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the engine assembly and slide the clip to secure it.
      GTY343021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Up
      *b for LH Side
      *c Do not position hose clamp claws in this area

      HINT: 

      Make sure that the claws on the hose clamp are positioned as shown in the illustration.

  27. INSTALL INVERTER BRACKET ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Temporarily install the inverter bracket assembly with the 4 bolts.
    2. Tighten the 4 bolts in the order shown in the illustration.
      Fig 3: Inverter Bracket Assembly Bolts Tightening Sequence
      GTY719716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    3. Connect the earth wire with the bolt.

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

    4. Install the inverter reservoir tank assembly with the 2 bolts.

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

    5. Connect the 2 wire harness clamps.
      GTY717559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the motor cable protector with the bolt.
      GTY717558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  28. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  29. INSTALL AIR CLEANER CAP SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  30. INSTALL INVERTER WITH CONVERTER ASSEMBLY 

    (Refer to INSTALLATION [11/2015 - ] )

  31. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 16

  32. INSTALL FRONT NO. 1 VENTILATOR SEAL 

    Refer to PROCEDURE - Step 17

  33. INSTALL FRONT AIR SHUTTER SEAL 

    Refer to PROCEDURE - Step 18

  34. INSTALL INNER COWL TOP TO COWL BRACE 

    Refer to PROCEDURE - Step 19

  35. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    (Refer to INSTALLATION [11/2015 - ] )

  36. ADD COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  37. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 2

  38. ADD HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 2

  39. INSPECT HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 1

  40. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 4

  41. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    (Refer to INSTALLATION [11/2015 - 06/2017] )

  42. INSTALL SERVICE PLUG GRIP 

    (Refer to INSTALLATION [11/2015 - 06/2017] )

  43. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  44. WARM UP COMPRESSOR 

    Refer to PROCEDURE - Step 3

  45. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 4

  46. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1

  47. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  48. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1

  49. INSPECT FOR COOLANT LEAK (for Inverter) 

    Refer to PROCEDURE - Step 1

  50. INSPECT FOR HYBRID TRANSAXLE FLUID LEAK 
  51. INSPECT FOR OIL LEAK 
  52. INSPECT FOR EXHAUST GAS LEAK 
  53. INSPECT IGNITION TIMING 

    See step  6

  54. INSPECT ENGINE IDLE SPEED 

    See step  7

  55. INSPECT CO/HC 

    See step  9

  56. INSPECT AND ADJUST SHIFT LEVER POSITION 

    (Refer to ADJUSTMENT [11/2015 - ] )

  57. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    (Refer to ADJUSTMENT [11/2015 - 06/2017] )

  58. CHECK FOR SPEED SENSOR SIGNAL 

    (Refer to TEST MODE PROCEDURE [11/2015 - ] )

  59. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY 
    1. Install the No. 1 engine under cover assembly with the 6 screws, 5 bolts and 2 clips.
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