OIL PUMP ASSEMBLY INSTALLATION

INSTALL OIL WITH MOTOR PUMP ASSEMBLY
1. Install a new gasket to the oil with motor pump assembly.
2. Using SST, install the oil with motor pump assembly with the 4 bolts.
  
  SST
  
  09961-00950
  
  Torque:
  
  without SST
  
  32 N*m { 321 kgf*cm, 24 ft.*lbf }
  
  with SST
  
  18 N*m { 180 kgf*cm, 13 ft.*lbf }
  Tech Tips
  
  Use a torque wrench with a fulcrum length of 180 mm (7.09 in.).
  
  If using a torque wrench with a length other than 180 mm (7.09 in.), the specified torque value must be recalculated.
3. Connect the transmission breather hose.
INSTALL OIL COOLER TUBE (for LHD)
1. Install the oil cooler tube with the 2 clips and the 3 bolts in the order shown in the illustration.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL OIL COOLER TUBE (for RHD)
1. Install the oil cooler tube with the 2 clips and the 3 bolts in the order shown in the illustration.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
2. Install the wire harness clamp bracket with the bolt.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
CONNECT OUTLET NO. 1 HYBRID WATER PUMP PIPE (for LHD)
1. Install the outlet No. 1 hybrid water pump pipe with the 2 bolts.
  
  Torque:
  
  22 N*m { 224 kgf*cm, 16 ft.*lbf }
2. Secure the hose with the clip.
3. Secure the hose with the clip.
CONNECT WIRE HARNESS
1. Install the 9 wire harness clamps and connector to the hybrid vehicle transmission assembly.
INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY
1. Install the bracket with the 2 bolts.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
2. Install the front exhaust pipe to the exhaust manifold LH and RH with the 2 bolts and 2 new nuts.
  
  Torque:
  
  39 N*m { 398 kgf*cm, 29 ft.*lbf }
CONNECT OUTLET OIL COOLER HOSE
1. Connect the No. 2 oil cooler outlet hose to the radiator assembly.
CONNECT INLET OIL COOLER HOSE
1. Connect the No. 2 oil cooler inlet hose to the radiator assembly.
INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR
1. Install the front lower suspension member protector with the 9 bolts.
  
  Torque:
  
  for bolt A
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  except bolt A
  
  58 N*m { 593 kgf*cm, 43 ft.*lbf }
INSTALL NO. 1 ENGINE UNDER COVER
1. Install the No. 1 engine under cover with the 13 screws and 7 clips.
INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

Tech Tips

Use the same procedure described for the LH side.
INSTALL FRONT WHEEL OPENING EXTENSION PAD LH
1. Install the front wheel opening extension pad LH with the 5 screws.
CONNECT OIL PUMP MOTOR CONTROLLER CONNECTOR
1. Applicable period (2007/04 - 2007/12)
  1. Connect the power line connector and securely lock the lock lever as shown in the illustration.
    
    Note
    
    Push the connector all the way in and lock the lock lever.
    
    Be sure to securely lock the claw of the connector.
    
    Tech Tips
    
    When the connector is pushed all the way in, the lock lever will move slightly to the lock position.
  2. Install the clamp to the bracket.
  3. Push the lock into the connector to securely lock the lock lever of the power line connector.
2. Applicable period (2007/12 -)
  1. Connect the power line connector and securely lock the lock lever as shown in the illustration.
    
    Note
    
    Push the connector all the way in and lock the lock lever.
    
    Be sure to securely lock the claw of the connector.
    
    Tech Tips
    
    When the connector is pushed all the way in, the lock lever will move slightly to the lock position.
  2. Install the clamp to the bracket.
  3. Push the lock into the connector to securely lock the lock lever of the power line connector.
3. Connect the signal line connector to the oil pump motor controller.
INSTALL INTAKE AIR CONNECTOR PIPE
1. Align the protrusion of the intake air resonator with the cutout of the bracket and insert the protrusion.
2. Install the intake air connector pipe with the 3 hose clamps.
  
  Torque:
  
  for intake air connector pipe and throttle body
  
  4.8 N*m { 49 kgf*cm, 42 in.*lbf }
  
  for intake air connector pipe and intake air resonator
  
  3.8 N*m { 39 kgf*cm, 34 in.*lbf }
  
  Note
  
  Insert the protrusion of the intake air connector pipe into the hole of the hose clamp.
  Tech Tips
  - The intake air connector pipe and throttle body clamp can be tightened within the range of 4.0 N*m (41 kgf*cm, 35 in.*lbf) to 5.5 N*m (56 kgf*cm, 49 in.*lbf), and the intake air connector pipe and intake air resonator clamp can be tightened within the range of 2.0 N*m (20 kgf*cm, 18 in.*lbf) to 5.5 N*m (56 kgf*cm, 49 in.*lbf).
  - When tightening the hose clamp, make sure the hose clamp's end is within the painted white line (width: 2 mm (0.0787 in.)).
3. Attach the 2 wire harness clamps.
4. Connect the No. 1 ventilation hose and No. 2 ventilation hose to the intake air connector pipe.
  Tech Tips
  
  Position the claws of the clamps as shown in the illustration.
  
  Install the clamps so that they are within the hose's paint marks.
INSTALL COOL AIR INTAKE DUCT SEAL
1. Install the cool air intake duct seal with the 4 clips.
INSTALL ENGINE ROOM SIDE COVER LH
1. Install the engine room side cover LH with the 5 clips.
INSTALL ENGINE ROOM SIDE COVER RH
1. Install the engine room side cover RH with the 5 clips.
INSTALL NO. 1 AIR CLEANER INLET
1. Align the holes with the connection areas labeled A, and attach the No. 1 air cleaner inlet.
2. Install the No. 1 air cleaner inlet with the 2 bolts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY
1. Attach the 4 clips labeled B.
  Note
  
  Make sure the clips are attached securely.
  
  Attaching the clips forcefully or hitting the top of the clips may damage them.
2. Install the air cleaner inlet cover sub-assembly with the 5 clips labeled A.
INSTALL V-BANK COVER SUB-ASSEMBLY
1. After sliding the V-bank cover sub-assembly from the vehicle front to the rear to attach the 2 clips labeled A, attach the 4 clips labeled B and install the V-bank cover sub-assembly.
  CAUTION:
  
  Make sure the clips are attached securely.
  
  Attaching the clips forcefully or hitting the top of the clips may damage them.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

ADD INVERTER COOLANT (for LHD)

Note

Do not reuse the drained coolant because it may contain foreign objects.

If the vehicle is driven with air in the inverter cooling system, the following DTCs may be set.

DTC Code	Detection Item
P0A01-725	Motor Electronics Coolant Temperature Sensor Circuit Range / Performance
P0A01-726	Motor Electronics Coolant Temperature Sensor Circuit Range / Performance
P0A78-284	Drive Motor "A" Inverter Performance
P0A7A-322	Generator Inverter Performance
P0A93-346	Inverter Cooling System Performance
P0A94-553	DC / DC Converter Performance
P0AEE-276	Motor Inverter Temperature Sensor "A" Circuit Range / Performance
P0AEE-277	Motor Inverter Temperature Sensor "A" Circuit Range / Performance
P3221-314	Generator Inverter Temperature Sensor Circuit Range / Performance
P3221-315	Generator Inverter Temperature Sensor Circuit Range / Performance
P3226-562	DC/DC Boost Converter Temperature Sensor
P3226-563	DC/DC Boost Converter Temperature Sensor

Tech Tips

for LHD:

Coolant (for inverter) capacity: 2.6 liters (2.7 US qts, 2.3 Imp. qts.)
for RHD:

Coolant (for inverter) capacity: 2.5 liters (2.5 US qts, 2.2 Imp. qts.)

for LHD:

Remove the 2 clips and 2 plugs from the tubes.

Note

Do not reuse the clips or plugs.
for RHD:

Remove the clip and plug from the tube.

Note

Do not reuse the clip or plug.
Add coolant to the reserve tank.
for LHD:

Install 2 new plugs and 2 new clips to the tubes.
for RHD:

Install a new plug and new clip to the tube.
Connect the intelligent tester to the DLC3.
Select the following menu items: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

Tech Tips

The water pump can also be operated using inspection mode Click here.
While adding coolant so that the coolant level is kept around the FULL line of the inverter reserve tank, operate the water pump for 3 minutes or more and then stop it for 1 minute or more.

While adding coolant so that the coolant level is kept around the FULL line of the inverter reserve tank, operate the water pump for 1 minute or more and stop it for 1 minute or more. Repeat this procedure until bleeding is completed.

Standard
When the operation sound of the water pump becomes small or when no air bubbles can be seen in the inverter reserve tank, bleeding of the coolant system is complete.

Tech Tips

If the water pump operates without a sufficient amount of coolant for approximately 5 seconds, the protective circuit will activate to stop the water pump for approximately 15 seconds. If a sufficient amount of coolant is added, the water pump will start operating automatically.
If an excessive amount of coolant is added to the inverter reserve tank, coolant may overflow when operation of the water pump is stopped.

After bleeding is completed, add coolant to the FULL level, and install the inverter reserve tank cap.

Note

Make sure to add more coolant than was drained initially.

INSPECT FOR INVERTER COOLANT LEAK (for LHD)
1. Remove the reserve tank cap.
  
  CAUTION:
  
  To avoid the danger of being burned, do not remove the reserve tank cap while the coolant for the inverter is still hot.
2. Install the radiator cap tester.
3. Pump the radiator cap tester to 37 kPa (0.38 kgf/ cm², 5.4 psi), and then check that the pressure does not drop.
  
  Tech Tips
  
  If the pressure drops, check the hoses, radiator, water pump, inverter with converter, and hybrid vehicle transaxle assembly for leakage.
4. Reinstall the reserve tank cap.
ADD TRANSMISSION FLUID
1. Add transmission fluid Click here.
B1 AIR BLEEDING
1. Inspect the Control the Shift Position Click here.
2. Connect the intelligent tester to the DLC3.
3. Turn the power switch on (READY) and turn the intelligent tester on.
  Note
  - Make sure that the shift lever is in P and the air conditioning is off before turning the power switch on (READY) and turning the intelligent tester on.
  - Make sure that no DTCs are output.
  - Make sure that the transmission fluid temperature is between 0°C and 79°C (32°F to 175°F).
4. Enter the following menus: Powertrain / Hybrid Control / Utility / B1 Air Bleeding.
  Note
  - Do not move the shift lever from P.
  - Do not turn on the air conditioning while bleeding the air from the B1 chamber.
  Tech Tips
  
  It takes about 10 minutes to bleed the air from the B1 chamber.
5. Inspect the Control the Shift Position Click here.
INSTALL NO. 2 ENGINE UNDER COVER
1. Install the No. 2 engine under cover with the 4 screws and 2 clips.
INSTALL FRONT CENTER FLOOR COVER (w/ Cover)
1. Install the front center floor cover with the 3 screws, 2 bolts and clip.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
INSTALL BATTERY SERVICE HOLE COVER LH
1. Text in Illustration
  
  *A for Standard
  
  *B for Ottoman
  
  Attach the battery service hole cover LH with the clip and fastening tape.
INSTALL DECK TRIM SIDE BOARD LH (w/o Spare Tire)
1. Attach the 2 clips to install the deck trim side board LH.
INSTALL DECK BOARD ASSEMBLY (w/o Spare Tire)
INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)