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Home >> Toyota >> 2018 >> Prius Two Eco >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - Service Information (2 Of 2) >> Engine Assembly & Engine Under Cover >> Installation [12/2018 - 07/2020] >> Procedure

Installation [12/2018 - 07/2020]: Procedure

  1. INSTALL ENGINE HANGERS 

    Refer to PROCEDURE - Step 59

  2. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND 
    1. Remove the engine assembly from the engine stand.
  3. INSTALL FLYWHEEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  4. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  5. INSTALL ENGINE ASSEMBLY 

    Refer to PROCEDURE - Step 10

  6. INSTALL ENGINE WIRE 
    1. Install the engine wire to the engine assembly with transaxle.
  7. INSTALL FLYWHEEL HOUSING SIDE COVER 

    Refer to PROCEDURE - Step 11

  8. INSTALL STARTER HOLE INSULATOR 

    Refer to PROCEDURE - Step 12

  9. 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. Install the engine mounting insulator sub-assembly RH with the 2 bolts and nut.
      GTY598245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
      *b Nut

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

      NOTE:

      Temporarily tighten the bolt (A), and then fully tighten the 2 bolts and nut in the order of (B), (A), and (C).

    2. Connect the 2 cooler brackets to the engine mounting insulator sub-assembly RH with the bolt and nut.

      Bolt 

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

      Nut 

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

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

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

      GTY606692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL ENGINE MOUNTING INSULATOR LH 

    HINT: 

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

    1. Install the engine mounting insulator LH with the 4 bolts and nut.

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

      GTY934644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
      *b Nut
      NOTE:

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

  11. 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:
      • 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 2 bolts, No. 1 engine hanger and No. 2 engine hanger.
    3. Install the wiring harness clamp bracket to the cylinder head sub-assembly with the bolt.

      Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

    4. Engage the 3 clamps.
    5. 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.
    6. Connect the front suspension crossmember sub-assembly to the vehicle with the 4 bolts.

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

    7. Apply adhesive to 2 or 3 threads at the end of each of the bolt.
      GTY556845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

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

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

      GTY586182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Connect the engine mounting insulator LH to the hybrid vehicle transaxle assembly with the 3 bolts and nut.
      GTY583470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
      *b Nut

      Bolt 

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

      Nut 

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

    10. Connect the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 2 bolts.

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

      GTY567900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Install the nut.

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

  12. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 17

  13. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  14. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING 

    Refer to PROCEDURE - Step 1

  15. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 2

  16. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

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

    Refer to PROCEDURE - Step 2

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

    HINT: 

    Use the same procedure as for the LH side.

  19. INSTALL FRONT STABILIZER LINK ASSEMBLY LH 

    Refer to PROCEDURE - Step 13

  20. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  21. CONNECT TIE ROD END SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 10

  22. CONNECT TIE ROD END SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  23. INSTALL FRONT SPEED SENSOR LH 

    Refer to PROCEDURE - Step 15

  24. INSTALL FRONT SPEED SENSOR RH 

    HINT: 

    Use the same procedure as for the LH side.

  25. INSTALL FRONT AXLE SHAFT NUT LH 

    Refer to PROCEDURE - Step 8

  26. INSTALL FRONT AXLE SHAFT NUT RH 

    HINT: 

    Use the same procedure as for the LH side.

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

    Refer to PROCEDURE - Step 5

  28. INSTALL FRONT CENTER FLOOR BRACE 

    Refer to PROCEDURE - Step 10

  29. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 11

  30. INSTALL FRONT FLOOR COVER RH 

    HINT: 

    Use the same procedure as for the LH side.

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

    Refer to PROCEDURE - Step 14

  32. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 4

  33. INSTALL COLUMN HOLE COVER SILENCER SHEET 

    Refer to PROCEDURE - Step 5

  34. CONNECT NO. 3 ENGINE WIRE 
    1. Connect the No. 3 engine wire to hybrid vehicle transaxle assembly with the bolt.

      Torque: 12.5 N*m (127 kgf*cm, 9 ft.*lbf) 

    2. Engage the clamp.
  35. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 
    1. Temporarily install the compressor with motor assembly with the bolt (A).
      Fig 1: Bolt Tightening Sequence
      GTY591685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt (A)
    2. Install the compressor with motor assembly with the 3 bolts.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      HINT: 

      Tighten the 3 bolts in the order shown in the illustration.

    3. Connect connector (B).
      GTY552007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Connector (A)
      *b Connector (B)
      *c Green-colored Lock
    4. Connect connector (A) and slide the green-colored lock as shown in the illustration to lock it securely.
      WARNING:

      Make sure to wear insulating gloves.

      NOTE:

      Make sure that the connector is connected securely.

    5. Connect the bracket with the bolt.

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

  36. 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.
  37. CONNECT INLET HYBRID RADIATOR HOSE 
    1. Connect the inlet hybrid radiator hose to the motor cooling cooler and slide the clip to secure it.
  38. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  39. CONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Connect the No. 1 fuel vapor feed hose to the fuel vapor feed pipe and slide the clip to secure it.
  40. CONNECT INLET HEATER WATER HOSE A 
    1. Connect the inlet heater water hose A to the EGR valve assembly and slide the clip to secure it.
  41. CONNECT OUTLET HEATER WATER HOSE E 
    1. Connect the outlet heater water hose E to the No. 1 water by-pass pipe and slide the clip to secure it.
  42. 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.
  43. CONNECT NO. 3 RADIATOR HOSE 
    1. Connect the No. 3 radiator hose to the water outlet and slide the clip to secure it.
    2. Install the 2 bolts to the hybrid vehicle transaxle assembly.

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

  44. INSTALL INVERTER WITH CONVERTER ASSEMBLY 

    Refer to INSTALLATION [11/2015 - ]

  45. INSTALL INLET NO. 1 AIR CLEANER 

    Refer to PROCEDURE - Step 12

  46. INSTALL AIR CLEANER BRACKET 

    Refer to PROCEDURE - Step 13

  47. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 14

  48. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 15

  49. INSTALL THROTTLE BODY ASSEMBLY 

    Refer to INSTALLATION [11/2015 - ]

  50. INSTALL INLET NO. 2 AIR CLEANER 

    Refer to PROCEDURE - Step 16

  51. INSTALL RADIATOR SUPPORT OPENING COVER 

    Refer to PROCEDURE - Step 2

  52. CONNECT NO. 8 WATER BY-PASS HOSE 
    1. Connect the No. 8 water by-pass hose to the No. 2 water by-pass hose assembly and slide the clip to secure it.
  53. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 5

  54. ADD HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 3

  55. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 3

  56. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1

  57. INSPECT HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 2

  58. INSPECT FOR COOLANT LEAK (for Inverter) 

    Refer to PROCEDURE - Step 1

  59. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1

  60. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  61. INSPECT FOR OIL LEAK 

    Refer to PROCEDURE - Step 6

  62. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 6

  63. INSTALL NO. 2 ENGINE UNDER COVER 
    1. Install the No. 2 engine under cover with the 3 bolts.

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

  64. INSTALL REAR MOTOR UNDER COVER LH 
    1. except Rough Road Area Specification Vehicles:
      1. Install the rear motor under cover LH with the 4 clips and screw.
    2. for Rough Road Area Specification Vehicles:
      1. Install the rear motor under cover LH with the 5 clips and screw.
  65. INSTALL REAR MOTOR UNDER COVER RH 
    1. except Rough Road Area Specification Vehicles:
      1. Install the rear motor under cover RH with the 4 clips and screw.
    2. for Rough Road Area Specification Vehicles:
      1. Install the rear motor under cover RH with the 5 clips and screw.
  66. INSTALL NO. 1 ENGINE UNDER COVER 
    1. Install the No. 1 engine under cover with the 10 clips and 4 bolts.

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

  67. INSTALL FRONT WHEELS 

    Refer to INSTALLATION [12/2018 - ]

  68. INSPECT IGNITION TIMING 

    Refer to PROCEDURE - Step 7 [08/2016 - 08/2019] , or refer to PROCEDURE - Step 7 [08/2019 - ]

  69. INSPECT ENGINE IDLE SPEED 

    Refer to PROCEDURE - Step 8 [08/2016 - 08/2019] , or refer to PROCEDURE - Step 8 [08/2019 - ]

  70. INSPECT CO/HC 

    Refer to PROCEDURE - Step 10 [08/2016 - 08/2019] , or refer to PROCEDURE - Step 10 [08/2019 - ]

  71. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [12/2018 - 07/2020]

  72. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Engage the 3 clips to install the No. 1 engine cover sub-assembly.
      NOTE:
      • Be sure to engage the clips securely.
      • Do not apply excessive force or hit the No. 1 engine cover sub-assembly to engage the clips. This may cause the No. 1 engine cover sub-assembly to break.
  73. CHECK SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [12/2018 - 07/2020]

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