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Home >> Toyota >> 2025 >> RAV4 Plug-In Hybrid SE >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical System (A25A-FXS) - Service Information (2 Of 3) (PHEV) >> Engine Assembly >> Installation [06/2020 - ] >> Procedure

Installation [06/2020 - ]: Procedure

  1. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH 

    HINT: 

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

    1. Install the engine mounting insulator sub-assembly LH with the 2 bolts and nut.

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

      NOTE:

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

      GTY998232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  2. INSTALL ENGINE MOUNTING SPACER 

    HINT: 

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

    1. Install the engine mounting spacer to the vehicle body with the 2 bolts.

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

      NOTE:

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

      GTY997189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. 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.

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

      NOTE:

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

      GTY998005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Install the bolt to connect the No. 2 ground wire.

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

      GTY997737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the radiator reserve tank assembly as shown in the illustration.
      GTY997498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      No. 6 Water By-pass Hose
      Connector
      Install in this Direction
    4. Connect the No. 6 water by-pass hose, connectors and attach the clamps.
    5. Install the bolt and nut in the order shown in the illustration.

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

      Fig 1: Radiator Reserve Tank Assembly Tightening Sequence
      GTY997887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    6. Connect the air conditioning tube and accessory assembly with the bolt.
      GTY997717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  4. INSTALL NO. 1 INVERTER RESERVE TANK BRACKET 
    1. Install the No. 1 inverter reserve tank bracket with the bolt.

      Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) 

  5. INSTALL ENGINE HANGERS 

    See step  61 [06/2020 - 12/2021], or see step  61 [12/2021 - 10/2022], or see step  61 [10/2022 - ]

  6. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND 
    1. Remove the engine assembly from the engine stand.
  7. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE 

    Refer to PROCEDURE - Step 2

  8. INSTALL FLYWHEEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  9. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY 

    Refer to PROCEDURE - Step 4

  10. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 12

  11. INSTALL FLYWHEEL HOUSING SIDE COVER 

    Refer to PROCEDURE - Step 18

  12. INSTALL OIL PUMP WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  13. INSTALL HV AIR CONDITIONING WIRE 
    1. Attach the guide to install the HV air conditioning wire to the hybrid vehicle transaxle assembly.
      GTY997723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 2 bolts.

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

    3. Connect the connector and slide the green-colored lock as shown in the illustration to lock it securely.
      WARNING:

      Make sure to wear insulated gloves.

      NOTE:

      Make sure that the connector is connected securely.

      GTY744925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Green-colored Lock
      Slide
    4. Attach the clamps.
      GTY997930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL ENGINE WIRE 
    1. Install the engine wire to the engine assembly.
  15. INSTALL REAR ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Align and insert the protrusion of the rear engine mounting insulator bracket into the gap between the 2 inner walls of the rear engine mounting insulator to align the hole of the engine mounting insulator bracket with the bolt hole of the rear engine mounting insulator, and install the rear engine mounting insulator with the bolt.

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

      GTY1000193Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Engine Mounting Bracket
      *2 Rear Engine Mounting Insulator
      *a Protrusion
      *b Hole
      *c Wall
      *d Gap
    2. Attach the clamp to connect the engine wire.
  16. INSTALL WIRING HARNESS CLAMP BRACKET 
    1. GTY1000905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the wiring harness clamp bracket with the bolt.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

    2. Attach the clamps to connect the engine wire.
  17. INSTALL FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    Refer to PROCEDURE - Step 16

  18. INSTALL FRONT ENGINE SUPPORT MEMBER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  19. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover to the cylinder block sub-assembly.
  20. REMOVE ENGINE HANGERS 
    1. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and engine mounting bracket RH.
  21. INSTALL FUEL DELIVERY GUARD 
    1. Install the fuel delivery guard to the engine mounting bracket RH with the bolt.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

  22. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 

    HINT: 

    Perform inspection after repair after replacing the engine assembly.

    Refer to INITIALIZATION [06/2020 - ]

    1. Set the engine assembly with transaxle on an engine lifter.
      GTY998032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Attachments - -
      NOTE:
      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle level.
      • 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.
    2. 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.
    3. Install the front bumper extension sub-assembly LH and front bumper extension sub-assembly RH to the front frame assembly and vehicle body with the 2 bolts (A), 2 bolts (B) and 4 nuts.

      Bolt (A) 

      Torque: 135 N*m (1377 kgf*cm, 100 ft.*lbf) 

      Bolt (B) 

      Torque: 9.5 N*m (97 kgf*cm, 84 in.*lbf) 

      Nut 

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

      GTY997373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Bumper Extension Sub-assembly LH
      *2 Front Bumper Extension Sub-assembly RH
      *3 Rear Front Suspension Member Brace LH
      *4 Rear Front Suspension Member Brace RH
      Bolt
      Nut
    4. Install the rear front suspension member brace LH and rear front suspension member brace RH to the front frame assembly and vehicle body with the 2 bolts (C) and 4 bolts (D).

      Bolt (C) 

      Torque: 135 N*m (1377 kgf*cm, 100 ft.*lbf) 

      Bolt (D) 

      Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

    5. Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 3 bolts and nut.

      Bolt 

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

      Nut 

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

      GTY997924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    6. Install the engine mounting insulator sub-assembly LH to the hybrid vehicle transaxle assembly with the 4 bolts.

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

      NOTE:

      Tighten the 4 bolts in the order of (A), (C), (B) and (D).

      GTY998250Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Loosen the bolt and retighten it.

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

      GTY1000972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the engine mounting stay LH to the engine mounting insulator sub-assembly LH with the 4 bolts.

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

      NOTE:

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

      GTY997598Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 11

  24. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 2

  25. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH 

    Refer to PROCEDURE - Step 3

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

    Refer to PROCEDURE - Step 4 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 4 [12/2021 - 10/2022] , or refer to PROCEDURE - Step 4 [10/2022 - ]

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

    HINT: 

    Use the same procedure described for the LH side.

  28. CONNECT TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 9

  29. CONNECT TIE ROD ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  30. CONNECT FRONT STABILIZER LINK ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  31. CONNECT FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  32. CONNECT FRONT SPEED SENSOR LH 

    Refer to PROCEDURE - Step 15 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 15 [12/2021 - 10/2022] , or refer to PROCEDURE - Step 15 [10/2022 - ]

  33. CONNECT FRONT SPEED SENSOR RH 

    HINT: 

    Use the same procedure described for the LH side.

  34. INSTALL FRONT AXLE SHAFT NUT LH 

    Refer to PROCEDURE - Step 8 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 8 [12/2021 - 10/2022] , or refer to PROCEDURE - Step 8 [10/2022 - ]

  35. INSTALL FRONT AXLE SHAFT NUT RH 

    HINT: 

    Use the same procedure described for the LH side.

  36. STAKE FRONT AXLE SHAFT NUT LH 

    Refer to PROCEDURE - Step 16 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 16 [12/2021 - 10/2022] , or refer to PROCEDURE - Step 16 [10/2022 - ]

  37. STAKE FRONT AXLE SHAFT NUT RH 

    HINT: 

    Use the same procedure described for the LH side.

  38. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 6

  39. INSTALL ENGINE UNDER COVER HEAT INSULATOR 
    1. Install the engine under cover heat insulator with the 2 bolts and 2 nuts.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

      GTY998276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Install the No. 23 traction battery bracket, then push the button to lock it.
      GTY999278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 23 Traction Battery Bracket
      *a Button
      *b Push
  40. INSTALL FRONT FLOOR COVER RH 
    1. Attach the clips to install the front floor cover RH.
      GTY997761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Clip
    2. Install the 2 bolts, 3 screws and clip.

      Bolt 

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

  41. INSTALL FRONT FLOOR COVER LH 
    1. Attach the clips to install the front floor cover LH.
      GTY1000860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Clip
    2. Install the 2 bolts, screw and 7 clips.

      Bolt 

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

  42. CONNECT FLOOR UNDER WIRE 
    WARNING:

    Be sure to wear insulated gloves.

    1. Connect the connector and slide the green-colored lock as shown in the illustration to lock it securely.
      GTY997795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Green-colored Lock
      Slide
      NOTE:

      Make sure that the connectors are connected securely.

  43. CONNECT WIRE HARNESS 
    1. Install the bolt to connect the ground wires.

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

      GTY997907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the clamp.
    3. Attach the claw to connect the wire harness to the engine room relay block and junction block assembly.
      GTY997910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the connectors to the engine room relay block and junction block assembly.
    5. Attach the claws and remove the No. 2 relay block cover.
      GTY997909Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. CONNECT NO. 1 TRANSMISSION OIL COOLER HOSE ASSEMBLY 
    1. Connect the No. 1 transmission oil cooler hose to the oil cooler assembly, and slide the clip to secure the hose. (Inlet Side)
      NOTE:
      • Align the direction of the claw on the clip with the paint mark on the hose.
      • Make sure the No. 1 transmission oil cooler hose is securely inserted to the stopper.
      GTY998229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 45° *b Paint Mark
      *c 2 to 7 mm (0.0787 to 0.276 in.) *d 0 to 3 mm (0 to 0.118 in.)
    2. Connect the No. 1 transmission oil cooler hose to the oil cooler assembly, and slide the clip to secure the hose. (Outlet Side)
      NOTE:
      • Align the direction of the claw on the clip with the paint mark on the hose.
      • Make sure the No. 1 transmission oil cooler hose is securely inserted to the stopper.
      GTY998229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 45° *b Paint Mark
      *c 2 to 7 mm (0.0787 to 0.276 in.) *d 0 to 3 mm (0 to 0.118 in.)
  45. CONNECT NO. 5 INVERTER COOLING HOSE 
    1. Connect the No. 5 inverter cooling hose to the motor cooling cooler, and slide the clip to secure the hose.
      NOTE:
      • Align the direction of the claw on the clip with the paint mark on the hose.
      • Make sure the No. 5 inverter cooling hose is securely inserted to the stopper.
      GTY997100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c Paint Mark *d Upper Side
      *e Front Side *f 2 to 7 mm (0.0787 to 0.276 in.)
  46. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the water inlet, and slide the clip to secure the hose.
      NOTE:
      • Align the direction of the claw on the clip with the paint mark on the hose.
      • Make sure the No. 2 radiator hose is securely inserted to the stopper.
      GTY997458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c Paint Mark *d Upper Side
      *e RH Side *f 2 to 7 mm (0.0787 to 0.276 in.)
  47. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the water outlet, and slide the clip to secure the hose.
      NOTE:
      • Align the direction of the claw on the clip with the paint mark on the hose.
      • Make sure the No. 1 radiator hose is securely inserted to the stopper.
    2. Attach the clamp.
      GTY997125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c Paint Mark *d Front Side
      *e RH Side *f 2 to 7 mm (0.0787 to 0.276 in.)
  48. CONNECT INLET HEATER WATER HOSE 
    1. Align the protrusions of the inlet heater water hose connector with the cutouts in the flow shutting valve (water by-pass hose assembly) and securely insert the inlet heater water hose connector to the stopper of the pipe.
      GTY921829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Push in the retainer.
      GTY1000757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Push
      Push in
    3. Check that the flow shutting valve (water by-pass hose assembly) and inlet heater hose connector are securely connected by pulling on them.
  49. CONNECT OUTLET HEATER WATER HOSE 
    1. Align the protrusion of the No. 2 water by-pass pipe sub-assembly with the cutout in the outlet heater water hose connector and securely insert the outlet heater water hose connector to the stopper of the pipe.
      GTY915786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Push in the retainer.
      GTY1000134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Push
      Push in
    3. Check that the No. 2 water by-pass pipe sub-assembly and outlet heater hose connector are securely connected by pulling on them.
  50. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube sub-assembly.
      1. Connect the fuel tube sub-assembly to the fuel pipe.

        Refer to PRECAUTION [06/2020 - ]

        GTY1000908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 1 fuel pipe clamp to the fuel tube connector.

      Refer to PRECAUTION [06/2020 - ]

      GTY1000910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. CONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Connect the No. 1 fuel vapor feed hose to the purge VSV.
      GTY997667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the clamp.
  52. INSTALL NO. 5 WATER BY-PASS HOSE 
    1. Install the No. 5 water by-pass hose to the No. 3 water by-pass pipe and radiator assembly, and slide the clips to secure the hose.
      NOTE:
      • Align the direction of the claw on the clip with the paint mark on the hose.
      • Make sure the No. 5 water by-pass hose is securely inserted to the stopper.
      GTY998522Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b View B
      *c 360° *d Paint Mark
      *e Upper Side *f Front Side
      *g Rear Side *h 2 to 7 mm (0.0787 to 0.276 in.)
      *i 2 to 5 mm (0.0787 to 0.197 in.) - -
  53. INSTALL SUCTION HOSE SUB-ASSEMBLY 
    1. Remove the vinyl tape wrapped around the connection of the suction hose sub-assembly and suction hose sub-assembly.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor with motor assembly.

      Compressor Oil

      ND-OIL 11 or equivalent

    3. Install the O-ring to the suction hose sub-assembly.
      NOTE:

      Keep the O-ring and O-ring fitting surface free of foreign matter.

    4. Install the suction hose sub-assembly with the bolt.

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

      GTY997647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not apply excessive force to the suction hose sub-assembly.
      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)
  54. INSTALL INVERTER RESERVE TANK SUB-ASSEMBLY 
    1. Connect the No. 2 inverter cooling hose and No. 5 inverter cooling hose to the inverter reserve tank sub-assembly, and slide the clips to secure the hoses.
      NOTE:
      • Align the direction of the claw on the clip with the paint mark on the hose.
      • Make sure the No. 2 inverter cooling hose and No. 5 inverter cooling hose are securely inserted to the stopper.
      GTY998091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b View B
      *c 120° *d Paint Mark
      *e Upper Side *f RH Side
      *g 2 to 7 mm (0.0787 to 0.276 in.) - -
    2. Fit the pin of the inverter reserve tank sub-assembly into grommet as shown in the illustration.
      GTY997390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Grommet
    3. Install the inverter reserve tank sub-assembly with the 2 bolts.

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

  55. INSTALL NO. 3 COOLER BRACKET 
    1. Install the No. 3 cooler bracket with the nut.
      GTY997650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  56. INSTALL DISCHARGE HOSE SUB-ASSEMBLY 
    1. Remove the vinyl tape wrapped around the connection of the discharge hose sub-assembly and discharge hose sub-assembly.
    2. Sufficiently apply compressor oil to a new O-rings and the fitting surface of the compressor with motor assembly.

      Compressor Oil

      ND-OIL 11 or equivalent

      NOTE:

      Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.

    3. Install the O-rings to the discharge hose sub-assembly.
      NOTE:

      Keep the O-rings and O-rings fitting surface free of foreign matter.

    4. Install the discharge hose sub-assembly with the bolt B to the compressor with motor assembly.
      Fig 2: Discharge Hose Sub-Assembly Tightening Sequence
      GTY1001414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt A
      Bolt B
      Nut

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

    5. Install the discharge hose sub-assembly to the discharge tube.
    6. Install the nut and bolt A.

      HINT: 

      Tighten the nut and bolt A in the order shown in the illustration.

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

      NOTE:
      • Do not apply excessive force to the discharge hose sub-assembly.
      • Make sure not to cut the O-ring while installing it. (Cut O-rings cannot be installed)
  57. INSTALL HYBRID MOTOR CONTROL INVERTER ASSEMBLY 

    Refer to INSTALLATION [06/2020 - ]

  58. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 2

  59. INSTALL INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  60. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. GTY1001022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Attach the clips to install the No. 1 engine cover sub-assembly.

      NOTE:
      • Securely attach the clips.
      • If the clips are forcibly attached or struck with an object, they may be damaged.
  61. INSTALL FRONT BUMPER NO. 2 REINFORCEMENT 

    Refer to PROCEDURE - Step 4 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 4 [12/2021 - ]

  62. INSTALL FRONT LOWER BUMPER ABSORBER 
    1. Attach the claws to install the front lower bumper absorber.
      GTY997644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the clip.
  63. INSTALL ACCUMULATOR ASSEMBLY 

    Refer to INSTALLATION [06/2020 - ]

  64. INSTALL FRONT FENDER APRON SEAL LH 
    1. Install the front fender apron seal LH with the 2 bolts and clip.

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

      GTY915278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Clip
  65. INSTALL FRONT FENDER APRON SEAL RH 
    1. Install the front fender apron seal RH with the 2 bolts and clip.

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

      GTY927625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Clip
  66. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY 
    1. Install the No. 2 engine under cover assembly with the 2 bolts, screw and 7 clips.
      GTY997734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Clip

      Bolt 

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

  67. INSTALL NO. 1 ENGINE UNDER COVER 
    1. Attach the guide to install the No. 1 engine under cover.
    2. Install the 2 bolts and 6 screws.

      Bolt 

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

      GTY1000197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Screw
  68. INSTALL FRONT FENDER FRONT SPLASH SHIELD LH 
    1. Attach the clip to install the front fender front splash shield LH.
      GTY997634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 4 screws.
  69. INSTALL FRONT FENDER FRONT SPLASH SHIELD RH 
    1. Attach the clip to install the front fender front splash shield RH.
      GTY997627Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 4 screws.
  70. INSTALL SERVICE PLUG GRIP 

    Refer to INSTALLATION [06/2020 - 10/2022] , or refer to INSTALLATION [10/2022 - ]

  71. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL 

    Refer to PROCEDURE - Step 2 [06/2020 - 10/2022] , or refer to PROCEDURE - Step 2 [10/2022 - ]

  72. INSTALL BATTERY HOLE COVER 

    Refer to PROCEDURE - Step 3 [06/2020 - 10/2022] , or refer to PROCEDURE - Step 3 [10/2022 - ]

  73. INSTALL DECK BOARD ASSEMBLY 

    Refer to PROCEDURE - Step 4 [06/2020 - 10/2022] , or refer to PROCEDURE - Step 4 [10/2022 - ]

  74. INSPECT SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 2

  75. ADJUST SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 4

  76. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 5 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 5 [12/2021 - 10/2023] , or refer to PROCEDURE - Step 5 [10/2023 - ]

  77. ADD HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 7

  78. INSPECT HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 3

  79. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 1

  80. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  81. WARM UP COMPRESSOR 

    Refer to PROCEDURE - Step 3

  82. INSPECT FOR ENGINE OIL LEAK 

    Refer to PROCEDURE - Step 6 [06/2020 - 12/2021] , or refer to PROCEDURE - Step 6 [12/2021 - 10/2023] , or refer to PROCEDURE - Step 6 [10/2023 - ]

  83. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1

  84. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 4

  85. INSPECT FOR FUEL LEAK 

    Refer to ON-VEHICLE INSPECTION [06/2020 - ]

  86. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 9

  87. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1 [06/2020 - 10/2023] , or refer to PROCEDURE - Step 1 [10/2023 - ]

  88. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR 

    Refer to PROCEDURE - Step 2

  89. INSTALL FRONT WHEELS 

    Refer to INSTALLATION [06/2020 - ]

  90. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  91. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [06/2020 - ]

  92. INSPECT THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  93. INSPECT IGNITION TIMING 

    Refer to PROCEDURE - Step 7

  94. INSPECT ENGINE IDLE SPEED 

    Refer to PROCEDURE - Step 8

  95. INSPECT CO/HC 

    Refer to PROCEDURE - Step 10

  96. CHECK SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [06/2020 - ]

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