ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transmission is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

PROCEDURE


  1. INSTALL ENGINE HANGER

    Click here

  2. REMOVE ENGINE FROM ENGINE STAND


    1. Lift the engine, and remove it from the engine stand.

      Note

      With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

    2. Place the engine onto a waking bench.

  3. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. A000UDWE01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 90119-08216 )
      09330-00021

    2. Clean the bolts and their installation holes.

    3. A000U6DE01
      *1 Adhesive

      Apply adhesive to 2 or 3 threads of the bolt end.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the crankshaft angle sensor plate and flywheel sub-assembly on the crankshaft.

    5. A000YFJE03

      Uniformly install and tighten the 10 bolts in the sequence shown in the illustration.

      Torque:
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }

      Note

      Do not strike or damage the flywheel sub-assembly installation bolts. Be sure to handle them carefully.

    6. Mark the upside of each flywheel sub-assembly installation bolt with paint.

    7. Tighten the flywheel sub-assembly installation bolts 90°.

    8. Check that the painted marks are now at a 90° angle to the upside.

      Note

      Do not start the engine for at least 1 hour after the installation.

  4. INSTALL INPUT TRANSMISSION DAMPER COVER ASSEMBLY


    1. A000Y1UE01
      *1 Flywheel Side

      Install the input transmission damper cover assembly with the 9 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

      Note

      Make sure to insert the clutch disc in the correct direction.

  5. INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here

  6. INSTALL STARTER HOLE INSULATOR

    Click here

  7. INSTALL 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 }

  8. INSTALL OIL COOLER TUBE SUB-ASSEMBLY

    Click here

  9. INSTALL REAR NO. 2 ENGINE MOUNTING INSULATOR

    Tech Tips

    Only perform this procedure when replacement of the rear No. 2 engine mounting insulator is necessary.


    1. Install the rear No. 2 engine mounting insulator with the 2 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  10. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    Only perform this procedure when replacement of the rear No. 1 engine mounting insulator is necessary.


    1. Install the 2 rear No. 1 engine mounting insulators with the 4 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  11. INSTALL REAR ENGINE MOUNTING MEMBER

    Tech Tips

    Only perform this procedure when replacement of the rear engine mounting member is necessary.


    1. Install the rear engine mounting member and No. 3 mounting insulator with the 5 nuts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  12. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  13. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET LH


    1. A000Z40

      Temporarily install the front No. 2 engine mounting bracket LH with the 2 nuts.

    2. A000UU5

      Temporarily install the front No. 1 engine mounting bracket LH with the 5 bolts.

    3. Tighten the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    4. Remove the 5 bolts and front No. 1 engine mounting bracket LH.

  14. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET RH


    1. A000XKI

      Temporarily install the front No. 2 engine mounting bracket RH with the 2 nuts.

    2. A000TCT

      Temporarily install the front No. 1 engine mounting bracket RH with the 5 bolts.

    3. Tighten the 2 nuts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    4. Remove the 5 bolts and front No. 1 engine mounting bracket RH.

  15. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  17. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Install the front No. 1 engine mounting bracket LH with the 5 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  18. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Install the front No. 1 engine mounting bracket RH with the 5 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  19. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Install the 2 spacers and 2 front engine mounting insulators with the 2 nuts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  20. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  21. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  22. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the engine oil level dipstick guide.

    3. Install the engine oil level dipstick guide with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Install the engine oil level dipstick.

  23. INSTALL FRONT FRAME ASSEMBLY


    1. Slowly lower the engine and set it to the front frame assembly.

    2. Install the 4 nuts.

      Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

    3. Attach the 2 clips and connect the heater wire connector.

  24. INSTALL ENGINE AND TRANSMISSION


    1. Place the engine on a engine lifter.

      Note


      • Place wooden blocks or plate lift attachments so that the engine is level.

      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

      • Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.

    2. Remove the 2 bolts and 2 engine hangers.

    3. Operate the engine lifter, then install the engine to the vehicle.

      Note

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

    4. A000UR8

      Align the front frame to the marks on the vehicle, and temporarily install the front frame with the 4 bolts.

      Note

      Make sure the crossmember is aligned to the vehicle marks as accurately as possible. If not performed accurately, the suspension alignment may become extremely misaligned.

    5. A000XNA

      Install the 4 rear engine mounting member's bolts.

      Torque:
      35 N*m  { 354 kgf*cm, 26 ft.*lbf }
    6. A000UIJ

      Tighten the 4 front frame bolts.

      Torque:
      165 N*m  { 1683 kgf*cm, 122 ft.*lbf }

  25. CONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY LH


    1. Connect the front lower shock absorber bracket sub-assembly LH. Then install the bolt.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  26. CONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY RH


    1. Connect the front lower shock absorber bracket sub-assembly RH. Then install the bolt.

      Torque:
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  27. CONNECT TRANSMISSION CONTROL SHAFT LEVER


    1. Connect the transmission control shaft lever and spring washer with the nut.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

  28. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click here

  29. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  30. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here.

  31. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  32. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY (for LHD)


    1. Attach the 2 claws to install the No. 2 air duct sub-assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  33. INSTALL NO. 1 AIR DUCT SUB-ASSEMBLY (for RHD)


    1. Attach the 2 claws to install the No. 1 air duct sub-assembly with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  34. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY

    Click here

  35. CONNECT HOSES AND CONNECTORS


    1. for LHD:


      1. A000YR7

        Connect the 2 heater hoses.

      2. A000V98

        Connect the purge line hose and No. 5 inverter cooling hose.

      3. A000U6G

        Connect the heater wire connector.

    2. for RHD:


      1. A000Z2I

        Connect the 2 heater hoses and No. 6 inverter cooling hose.

      2. A000UCE

        Connect the purge line hose and No. 2 inverter cooling hose.

      3. A000X3R

        Connect the heater wire connector.

    3. A000UAJ

      Attach the 5 clamps and connect the 2 connectors.

    4. A000XRQ

      Install the heater water pump and bracket with the 2 nuts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    5. Connect the heater water pump connector.

    6. Install the inverter cooling pipe bracket with the nut. Then attach the 2 clamps.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    7. A000TPM

      Connect the 2 oil pump motor controller connectors.

      Tech Tips

      Refer to the following procedures to connect the oil pump driver connector Click here.

    8. Install the ground wire with the nut.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
    9. A000VJ3

      Connect the 3 connectors to the front controller and attach the clamp.

    10. A000Z7F

      Lift up the wiring harness support and connect the 4 ECM connectors.

    11. A000XTDE03

      Install the wiring harness support to the ECM box.

    12. Attach the clip of connector A to the ECM box.

    13. Connect the 4 hybrid vehicle control ECU connectors and 2 wiring harness support connectors.

    14. A000TIH

      Install the engine room ECU box cover with the 3 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  36. INSTALL WATER PUMP ASSEMBLY WITH MOTOR AND BRACKET

    Click here

  37. CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape and/or plastic bags from the openings of the disconnected parts and motor compressor.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the motor compressor.

      Compressor oil
      ND-OIL 11 or equivalent

    3. Install the O-ring on the suction hose sub-assembly.

    4. Connect the suction hose sub-assembly to the motor compressor with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  38. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Remove the vinyl tape and/or plastic bags from the openings of the disconnected parts and motor compressor.

    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the motor compressor.

      Compressor oil
      ND-OIL 11 or equivalent

    3. Install the O-ring on the discharge hose sub-assembly.

    4. Connect the discharge hose sub-assembly to the motor compressor with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  39. CONNECT GENERATOR CABLE (for LHD)

    Click here

  40. CONNECT MOTOR CABLE (for LHD)

    Click here

  41. INSTALL INVERTER TERMINAL COVER (for LHD)

    Click here

  42. CONNECT GENERATOR CABLE (for RHD)

    Click here

  43. CONNECT MOTOR CABLE (for RHD)

    Click here

  44. INSTALL INVERTER TERMINAL COVER (for RHD)

    Click here

  45. CONNECT NO. 3 FUEL HOSE

    Click here

  46. CONNECT NO. 1 FUEL HOSE

    Click here

  47. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  48. INSTALL RESONATOR BRACKET SUB-ASSEMBLY

    Click here

  49. INSTALL NO. 2 RADIATOR HOSE

  50. INSTALL NO. 1 RADIATOR HOSE

  51. INSTALL OUTLET ENGINE ROOM ECM DUCT


    1. Install the outlet engine room ECM duct.

  52. INSTALL RADIATOR RESERVOIR ASSEMBLY

    Click here

  53. INSTALL AIR CLEANER ASSEMBLY RH

    Click here

  54. INSTALL AIR CLEANER ASSEMBLY LH

    Click here

  55. INSTALL INTAKE AIR CONNECTOR PIPE

    Click here

  56. INSTALL REAR FRAME SIDE RAIL


    1. A000WOSE03

      Install the 2 rear frame side rails with the 6 bolts and 4 nuts.

      Torque:
      for bolt A
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
      for nut B
      44 N*m  { 453 kgf*cm, 33 ft.*lbf }

  57. CONNECT FRONT ACTIVE STABILIZER CONTROL ACTUATOR CONNECTOR (w/ Active Stabilizer System)

    Click here

  58. INSTALL INLET ENGINE ROOM ECM DUCT (w/ Active Stabilizer System)

    Click here

  59. INSTALL NO. 3 COOL AIR INTAKE DUCT SUB-ASSEMBLY (w/ Active Stabilizer System)

    Click here

  60. CONNECT FRONT FENDER LINER LH (w/ Active Stabilizer System)

    Click here

  61. INSTALL FRONT BUMPER COVER

    Click here

  62. CONNECT OUTLET OIL COOLER HOSE

    Click here

  63. CONNECT INLET OIL COOLER HOSE

    Click here

  64. ADD FRONT DIFFERENTIAL OIL

    Click here

  65. ADD ENGINE COOLANT

    Click here

  66. ADD ENGINE OIL

    Click here

  67. INSTALL SERVICE PLUG GRIP

    Click here

  68. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  69. ADD COOLANT (for Inverter)

    Click here

  70. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  71. CHARGE REFRIGERANT

    Click here

  72. CHECK TRANSMISSION FLUID LEVEL

    Click here

  73. INSPECT FOR SHIFT LEVER POSITION

    Click here

  74. INSPECT FOR OIL LEAK

    Click here

  75. INSPECT FOR COOLANT LEAK

    Click here

  76. INSPECT FOR FUEL LEAK

    Click here

  77. INSPECT FOR REFRIGERANT LEAK

    Click here

  78. INSPECT FOR EXHAUST GAS LEAK

    Click here

  79. INSPECT IGNITION TIMING

    Click here

  80. INSPECT ENGINE IDLE SPEED

    Click here

  81. INSPECT CO/HC

    Click here

  82. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  83. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  84. MEASURE VEHICLE HEIGHT

    Click here

  85. ADJUST OBJECT RECOGNITION CAMERA

    Click here

  86. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. A000VISE03

      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 }

  87. INSTALL NO. 1 ENGINE UNDER COVER

    Click here

  88. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

    Click here

  89. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

    Click here

  90. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 4 screws and 2 clips.

  91. 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 }

  92. INSTALL INVERTER COVER ASSEMBLY LH (for RHD)


    1. Install the inverter cover assembly LH and attach the 2 clips.

  93. INSTALL INVERTER COVER ASSEMBLY RH (for LHD)


    1. Install the inverter cover assembly RH and attach the 2 clips.

  94. INSTALL MOTOR CABLE COVER LH (for RHD)


    1. Install the motor cable cover LH with the 2 clips.

  95. INSTALL MOTOR CABLE COVER RH (for LHD)


    1. Install the motor cable cover RH with the 2 clips.

  96. INSTALL COWL TOP VENTILATOR LOUVER RH (for LHD)

    Click here

  97. INSTALL COWL TOP VENTILATOR LOUVER LH (for RHD)

    Tech Tips

    Use the same procedures described for LHD vehicles.

  98. INSTALL ENGINE ROOM SIDE COVER LH

    Click here

  99. INSTALL ENGINE ROOM SIDE COVER RH

    Click here

  100. CHECK ENGINE COOLANT LEVEL

    Click here

  101. INSTALL NO. 1 AIR CLEANER INLET


    1. A000ZA5E03

      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 }

  102. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY


    1. A000U9HE04

      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.

  103. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A000XDYE03

      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.

  104. INSTALL BATTERY SERVICE HOLE COVER LH

    Click here

  105. INSTALL DECK TRIM SIDE BOARD LH (w/o Spare Tire)

    Click here

  106. INSTALL DECK BOARD ASSEMBLY (w/o Spare Tire)

    Click here

  107. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

    Click here