GENERATOR CABLE INSTALLATION


  1. INSTALL GENERATOR CABLE

    Note

    Wear insulated gloves.


    1. A01JBDJ

      Install the generator cable to the hybrid transaxle assembly with the 3 bolts.

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

      Note

      Keep the sealing surface of the generator cable and the connector terminal joint free of foreign matter.

    2. A01J9KJ

      Engage the 2 claws to install a new terminal cap.

      Note

      When installing the terminal cap to the generator cable terminal block, keep the sealing surface free of foreign matter.

    3. A01J9II

      Place the generator cable connector shell in position and install it with the 3 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    4. A01JBCA

      Connect the generator cable clamp to the motor cable bracket.

  2. INSTALL RADIATOR PIPE


    1. A01JD4D

      Install the radiator pipe with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    2. Connect the No. 3 radiator hose, No. 4 water by-pass hose and No. 1 radiator hose with the clamps.

  3. INSTALL INVERTER TRAY BRACKET


    1. A01JC8SE01

      Position the inverter tray bracket as shown in the illustration.

    2. Temporarily install bolt B to the inverter tray bracket.

    3. Tighten the 5 bolts to the inverter tray bracket in the order the bolt A, bolt C, bolt D, bolt E and bolt B.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    4. Connect the 2 clamps to the inverter tray bracket.

  4. INSTALL INVERTER RESERVE TANK ASSEMBLY


    1. A01JAHQE01

      Temporarily install bolt A to the inverter reserve tank assembly.

    2. Tighten the 2 bolts to the inverter reserve tank assembly in the order the bolt B and bolt A.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
  5. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A01JC7DE02

      Temporarily install the inverter with converter assembly with the 3 bolts.

      Note


      • Since the inverter with converter assembly is very heavy, 2 people are needed to install the inverter with converter assembly. When installing the inverter with converter assembly, do not damage the parts around it.

      • To prevent damage, do not hold the inverter with converter assembly by the connectors.

      • To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.

    2. Tighten the bolt A.

      Torque:
      12 N*m  { 122 kgf*cm, 8 ft.*lbf }
    3. Tighten the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 8 ft.*lbf }
  6. CONNECT WATER HOSE


    1. A01J8QE

      Connect the water hose to the inverter with converter assembly and lock the hose with the retainer.

      Note


      • Insert the retainer until a click sound is heard.

      • Pull on the hose to confirm that the hose is securely connected.

      • If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.

    2. A01JD0F

      Connect the water hose to the inverter with converter assembly and lock the hose with the retainer.

      Note


      • Insert the retainer until a click sound is heard.

      • Pull on the hose to confirm that the hose is securely connected.

      • If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.

  7. CONNECT NO. 2 ENGINE ROOM WIRE


    1. A01JBCN

      Disconnect the No. 2 engine room wire from the protector.

    2. A01J8E0

      Connect the No. 2 engine room wire with the bolt and 2 claws.

      Torque:
      8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

      Note

      Pass the No. 2 engine room wire under the two cooling hoses that pass beside the inverter.

    3. A01J9HQ

      Install the No. 1 relay block cover and 2 clamps.

    4. Install the relay block cover.

  8. REMOVE INVERTER TERMINAL COVER

    CAUTION:

    Wear insulating gloves.


    1. A01J95T

      Remove the 9 bolts and inverter terminal cover.

      Note

      Make sure to pull the inverter terminal cover straight up, as a connector is connected to the bottom of the cover.

  9. CONNECT NO. 2 ENGINE WIRE

    CAUTION:

    Wear insulating gloves.

    Note

    Do not allow any foreign objects or water to enter the inverter with converter assembly.


    1. A01J8MSE01

      Connect the No. 2 engine wire (high voltage cables of the air conditioning) with the 4 bolts to the inverter with converter assembly.

      Torque:
      Bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt B
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

      Note

      Be sure to use a torque wrench to tighten the bolts.

    2. A01JD0K

      Connect the harness clamp.

  10. CONNECT HIGH VOLTAGE CABLE OF FRONT TRANSAXLE

    CAUTION:

    Wear insulating gloves.

    Note

    Do not allow any foreign objects or water to enter the inverter with converter assembly.


    1. A01JCR0E01

      Connect the high voltage cable of the motor (MG2) with 5 bolts to the inverter with converter assembly.

      Torque:
      Bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt B
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

      Note

      Be sure to use a torque wrench to tighten the bolts.

    2. A01JBGU

      Connect the harness clamp.

    3. A01JC1ZE01

      Connect the high voltage cable of the generator (MG1) with the 5 bolts to the inverter with converter assembly.

      Torque:
      Bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt B
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

      Note

      Be sure to use a torque wrench to tighten the bolts.

    4. A01J8K6E01
      Text in Illustration
      *1 Align Mark

      Install the cable and cover.

      Note

      Close the cover so that the matchmarks are not visible.

  11. CONNECT FRAME WIRE

    CAUTION:

    Wear insulating gloves.

    Note


    • Make sure that the interlock is fully engaged.

    • Do not allow any foreign objects or water to enter the inverter with converter assembly.


    1. A01JCA9E02
      Text in Illustration
      *1 Front view of frame wire connector
      *2 Interlock
      *3 High voltage cables of the hybrid battery

      Connect the frame wire (high voltage cables of the hybrid battery) with the 4 bolts to the inverter with converter assembly.

      Torque:
      Bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt B
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

      Note


      • Be sure to use a torque wrench to tighten the bolts.

      • Make sure that the interlock is fully engaged.

    2. A01JCYX

      Connect the harness clamp.

  12. CHECK HIGH VOLTAGE CABLE CONNECTION

    CAUTION:

    Wear insulating gloves.

    Note

    Do not allow any foreign objects or water to enter the inverter with converter assembly.


    1. A01JD8Y

      Check that each connector and terminal is firmly installed.

      Note

      Make sure that the bolts are fully tightened.

  13. INSTALL INVERTER TERMINAL COVER

    CAUTION:

    Wear insulating gloves.

    Note


    • Make sure that the interlock is fully engaged.

    • Do not allow any foreign objects or water to enter the inverter with converter assembly.


    1. A01JCVEE01
      Text in Illustration
      *1 Interlock

      Install the inverter terminal cover with the 9 bolts to the inverter with converter assembly.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
  14. INSTALL ENGINE ROOM MAIN WIRE

    Note


    • Make sure that the connectors are fully engaged.

    • Do not allow any foreign objects or water to enter the inverter with converter assembly.


    1. A01JB3L

      Install the bolt, clamp and clip, and connect the engine room main ware.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A01JCZI

      Install the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    3. A01JBIC

      Connect the engine wire to the engine room main wire.

    4. A01JCYY

      Connect the connector to the inverter with converter assembly and lock the connector with the lock lever.

  15. INSTALL NO. 1 INVERTER BRACKET


    1. A01J9XBE01

      Temporarily install the No. 1 inverter bracket with the 3 bolts.

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

      Torque:
      14 N*m  { 140 kgf*cm, 10 ft.*lbf }
  16. INSTALL SERVICE PLUG GRIP

    CAUTION:

    Wear insulating gloves.

    Note

    Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.


    1. Wear insulated gloves and install the service plug grip in the order shown in the illustration.

      A01JARB
    2. Rotate the handle of the service plug grip 90° toward the battery and slide it in the direction shown by the arrow until a click sound is heard.

  17. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  18. INSTALL REAR NO. 3 FLOOR BOARD


    1. A01JC33

      Engage the 2 guides to install the rear No. 3 floor board.

  19. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  20. INSTALL REAR NO. 2 FLOOR BOARD


    1. A01JCWRE01

      Engage the 3 guides <A>.

    2. Engage the 2 guides <B> and install the rear No. 2 floor board as shown in the illustration.

  21. ADD COOLANT (for Inverter)

    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, damage may occur and the following DTCs may be set.

      DTC Code Detection Item
      P0A01-726 Motor Electronics Coolant Temperature Sensor Circuit Range / Performance
      P0A04-725 Motor Electronics Coolant Temperature Sensor Circuit Intermittent
      P0A08-264 DC / DC Converter Status Circuit
      P0A78-284 Drive Motor "A" Inverter Performance
      P0A78-286 Drive Motor "A" Inverter Performance
      P0A7A-322 Generator Inverter Performance
      P0A7A-324 Generator Inverter Performance
      P0A93-346 Inverter Cooling System Performance
      P0A94-553 DC / DC Converter Performance
      P0A94-557 DC / DC Converter Performance
      P0AEE-277 Motor Inverter Temperature Sensor "A" Circuit Range / Performance
      P0AF1-276 Drive Motor Inverter Temperature Sensor "A" Circuit Intermittent / Erratic
      P0BCD-315 Generator Inverter Temperature Sensor Circuit Range / Performance
      P0BD0-314 Generator Inverter Temperature Sensor Circuit Intermittent / Erratic
      P0C39-626 DC / DC Converter Temperature Sensor "A" Range / Performance
      P0C3C-625 DC / DC Converter Temperature Sensor "A" Intermittent / Erratic
      P0C3E-628 DC / DC Converter Temperature Sensor "B" Range / Performance
      P0C41-627 DC / DC Converter Temperature Sensor "B" Intermittent / Erratic
      P0C73-776 Motor Electronics Coolant Pump "A" Control Performance

    1. A01JBCU

      Slowly pour coolant into the reserve tank until it reaches the F line.

      Coolant quantity
      2.1 liters (2.2 US qts, 1.8 Imp. qts.)
    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

      2. Turn the power switch on (IG).

      3. On the intelligent tester, enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

      4. Keep the coolant at the F line in the reserve tank to compensate for the drop in coolant level when the air bleeds.

        Standard
        Air bleeding from the inverter cooling system is completed when the noise made by the water pump becomes smaller and the circulation of coolant in the reserve tank improves.

        Tech Tips

        Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the cooling system.

    3. When not using the intelligent tester:


      1. Turn the power switch on (READY). [*1]

      2. Turn the power switch off and add coolant to the F line because the coolant level drops as the air bleeds. [*2]

        Note


        • Be sure to turn the power switch off before adding SLLC.

        • Do not work on the components in the engine compartment while the vehicle is in the READY-on state because the engine is in intermittent operation.

      3. Repeat steps [*1] and [*2] until air bleeding from the cooling system is completed.

        Standard
        Air bleeding from the inverter cooling system is completed when the noise made by the water pump becomes smaller and the circulation of coolant in the reserve tank improves.

        Tech Tips

        Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the cooling system.

    4. After the air is completely bled from the cooling system, tighten the reserve tank cap.

    5. A01JBCU

      Add coolant to the F line of the reserve tank.

  22. ADD COOLANT (for Engine)


    1. Tighten the radiator drain cock plug.

    2. Remove the reservoir tank cap.

    3. A01JC0TE01
      Text in Illustration
      *1 B Line

      Add coolant to B line of the reservoir tank.

      Standard Capacity
      Item Capacity
      Engine coolant

      w/ Exhaust Heat Recirculation System:

      7.2 liters (7.6 US qts, 6.3 lmp. qts)

      w/o Exhaust Heat Recirculation System:

      6.5 liters (6.8 US qts, 5.7 lmp. qts)

      Tech Tips

      TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

      Note

      Never use water as a substitute for engine coolant.

    4. Squeeze the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

      If the coolant level is low, add coolant.

    5. Install the reservoir tank cap.

    6. Put the engine in inspection mode Click here.

    7. Bleed air from the cooling system.

      Note


      • Before starting the engine, turn the A/C switch off.

      • Adjust the heater control to the maximum hot setting.

      • Adjust the blower speed to low setting.


      1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes.

        Tech Tips

        The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

        CAUTION:

        When squeezing the radiator hose:
        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

      2. Squeeze the inlet and outlet radiator hoses several times by hand to bleed air from the system.

        CAUTION:

        When squeezing the radiator hose:
        • Wear protective gloves.

        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    8. A01JC0TE02
      Text in Illustration
      *1 Full Line
      *2 Low Line

      After the engine has cooled down, check that the coolant level is between full and low.

      If the coolant level is low, add coolant to the full line on the reservoir tank.

  23. INSPECT FOR COOLANT LEAK (for Inverter)


    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. A01JCGT

      Install the radiator cap tester.

    3. Pump the radiator cap tester to 122 kPa (1.2 kgf/ cm2, 17.7 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 leaks.

    4. Reinstall the reserve tank cap.

  24. INSPECT FOR COOLANT LEAK (for Engine)

    CAUTION:

    Do not remove the reservoir tank cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Note

    Before performing each inspection, turn the A/C switch off.


    1. Remove the reservoir tank cap.

    2. A01JB8R

      Fill the radiator and reservoir with coolant, and then attach a radiator cap tester.

    3. Put the engine in inspection mode Click here.

    4. Warm up the engine.

    5. Using the reservoir cap tester, increase the pressure inside the radiator to 108 kPa (1.1 kgf/cm2, 16 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator, front exhaust pipe assembly and the heater hose around and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

    6. Remove the radiator cap tester.

    7. Install the reservoir tank cap.

  25. INSTALL NO. 1 ENGINE UNDER COVER

  26. INSTALL FRONT LOWER BUMPER ABSORBER (w/ Cover)

  27. INSTALL FRONT SPOILER COVER (w/ Front Spoiler)

  28. INSTALL RADIATOR SUPPORT OPENING COVER


    1. Engage the 2 claws and install the radiator support opening cover.

    2. Install the 3 clips.