HYBRID VEHICLE TRANSAXLE INSTALLATION

INSTALL MOTOR CABLE BRACKET
1. Install the motor cable bracket with the bolt.
  
  Torque:
  
  23 N*m { 235 kgf*cm, 17 ft.*lbf }
INSTALL WIRE HARNESS CLAMP BRACKET
1. Install the 2 wire harness clamp brackets with the 2 bolts.
  
  Torque:
  
  23 N*m { 235 kgf*cm, 17 ft.*lbf }
INSTALL REAR ENGINE MOUNTING BRACKET
1. Install the rear engine mounting bracket with the 4 bolts in several steps.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
  
  Note
  
  Temporarily tighten bolt A, and then fully tighten the 4 bolts in the order of C, B, D and A.
INSTALL FRONT ENGINE MOUNTING BRACKET
1. Install the front engine mounting bracket with the 3 bolts in several steps.
  
  Torque:
  
  64 N*m { 653 kgf*cm, 47 ft.*lbf }
  
  Note
  
  Temporarily tighten bolt A, and then fully tighten the 3 bolts in the order of B, C and A.
SUPPORT HYBRID VEHICLE TRANSAXLE ASSEMBLY
1. Support the hybrid vehicle transaxle assembly with a transmission jack.
INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY
1. Text in Illustration
  
  *1 Knock Pin
  
  Make sure that the knock pins are installed to the engine.
2. Using an transmission jack, align the engine assembly and hybrid vehicle transaxle assembly, fit the knock pins into the knock pin holes, and tighten the 7 bolts shown in the illustration.
  
  Torque:
  
  33 N*m { 337 kgf*cm, 24 ft.*lbf }
  Note
  - Make sure to align the hybrid vehicle transaxle so that the input shaft of the hybrid vehicle transaxle will be inserted straight into the inner splines of the transmission input damper.
  - When inserting the input shaft of the hybrid vehicle transaxle into the inner splines of the transmission input damper, do not shake the hybrid vehicle transaxle excessively.
  - When mounting the hybrid vehicle transaxle to the engine, make sure to securely fit the knock pins into the knock holes.
  - Push in the hybrid vehicle transaxle so that the contact surfaces of the engine and the hybrid vehicle transaxle are aligned evenly.
  - While mounting the hybrid vehicle transaxle to the engine, temporarily tighten the bolt (A), fully tighten the bolt (B), fully tighten the bolt (A), and then fully tighten the bolts (C).
  - Do not hang the hybrid vehicle transaxle off of the engine if the contact surfaces of the engine and the hybrid vehicle transaxle are not in full contact. The knock holes of the hybrid vehicle transaxle case may be deformed due to the excessive weight of the engine and hybrid vehicle transaxle, resulting in misalignment between the engine and hybrid vehicle transaxle.
INSTALL ENGINE MOUNTING BRACKET LH
1. Install the engine mounting bracket LH with 3 new bolts in several steps.
  
  Torque:
  
  64 N*m { 653 kgf*cm, 47 ft.*lbf }
  
  Note
  
  Temporarily tighten bolt A, and then fully tighten the 3 bolts in the order of B, C and A.
2. Install the engine mounting insulator LH with the through bolt and nut.
  
  Torque:
  
  56 N*m { 571 kgf*cm, 41 ft.*lbf }
  
  Note
  
  When installing the engine mounting insulator, tighten the nut while holding the bolt.
INSTALL FRONT ENGINE MOUNTING INSULATOR
1. Temporarily install the front engine mounting insulator with the bolt and nut.
INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY
1. Install the front crossmember with the 4 bolts.
  
  Torque:
  
  99 N*m { 1010 kgf*cm, 73 ft.*lbf }
2. Install the front engine mounting insulator to the front crossmember with the 2 bolts.
  
  Torque:
  
  95 N*m { 969 kgf*cm, 70 ft.*lbf }
3. Tighten the front engine mounting insulator with the bolt and nut.
  
  Torque:
  
  145 N*m { 1479 kgf*cm, 107 ft.*lbf }
INSTALL REAR ENGINE MOUNTING INSULATOR
1. Install the rear engine mounting insulator to the engine mounting bracket with the through bolt.
  
  Torque:
  
  95 N*m { 969 kgf*cm, 70 ft.*lbf }
  
  Tech Tips
  
  Perform this procedure only when replacement of the engine mounting insulator is necessary.
INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
1. Support the front suspension crossmember with a jack.
2. While inserting SST into the reference holes on the front suspension crossmember RH and LH alternately, tighten the 2 bolts A, 2 bolts B and 2 nuts on the RH and LH sides to the respective specified torque in several steps.
  
  Text in Illustration
  
  *a Front Side
  
  SST
  
  09670-00020
  
  Torque:
  
  Bolt A
  
  145 N*m { 1479 kgf*cm, 107 ft.*lbf }
  
  Bolt B
  
  95 N*m { 969 kgf*cm, 70 ft.*lbf }
  
  Nut
  
  95 N*m { 969 kgf*cm, 70 ft.*lbf }
3. Install the 2 wire harness clamp brackets with the 2 bolts.
  
  Torque:
  
  13 N*m { 127 kgf*cm, 9 ft.*lbf }
INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH
1. Install the front suspension member rear brace LH with the 3 bolts and clip.
  
  Torque:
  
  Bolt A
  
  145 N*m { 1479 kgf*cm, 107 ft.*lbf }
  
  Bolt B
  
  93 N*m { 948 kgf*cm, 69 ft.*lbf }
INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

Tech Tips

Perform the same procedure as for the LH side.
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH
1. Install the front suspension member reinforcement LH with the 4 bolts.
  
  Torque:
  
  99 N*m { 1010 kgf*cm, 73 ft.*lbf }
  
  Note
  
  Temporarily tighten bolts A and B, and then fully tighten the 4 bolts in the order of C, B, D and A.
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH
1. Install the front suspension member reinforcement RH with the 4 bolts.
  
  Torque:
  
  99 N*m { 1010 kgf*cm, 73 ft.*lbf }
  
  Note
  
  Temporarily tighten bolts A and B, and then fully tighten the 4 bolts in the order of C, B, D and A.
INSTALL FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT
1. Install the front engine mounting bracket lower reinforcement with the 2 bolts.
  
  Torque:
  
  99 N*m { 1010 kgf*cm, 73 ft.*lbf }
INSTALL FLYWHEEL HOUSING SIDE COVER
1. Install the flywheel housing side cover.
INSTALL STARTER HOLE INSULATOR
1. Install the starter hole insulator with the 2 bolts.
  
  Torque:
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf }
REMOVE ENGINE HANGERS
1. Remove the 2 bolts and 2 engine hangers.
INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH
1. Install a new front drive shaft hole snap ring to the front drive inboard joint assembly.
  
  Tech Tips
  
  Face the end gap of the front drive inboard joint hole snap ring downward.
INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH

Tech Tips

Perform the same procedure as for the LH side.
INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
1. Coat the spline of the inboard joint shaft with transaxle fluid.
2. Align the shaft splines and tap in the drive shaft with a brass bar and a hammer.
  Note
  - Face the end gap of the front drive shaft hole snap ring downward.
  - Do not damage the transaxle case oil seal.
  - Do not damage the inboard joint boot.
  - Make sure to center the front drive shaft assembly during installation to prevent damage to the front drive shaft hole snap ring.
INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
INSTALL FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY LH
1. Connect the front No. 1 lower suspension arm sub-assembly to the front lower ball joint with the bolt and 2 nuts.
  
  Torque:
  
  89 N*m { 908 kgf*cm, 66 ft.*lbf }
INSTALL FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
INSTALL FRONT STABILIZER LINK ASSEMBLY LH
1. Install the front stabilizer link assembly to the front shock absorber with coil spring with the nut.
  
  Torque:
  
  74 N*m { 755 kgf*cm, 55 ft.*lbf }
  
  Tech Tips
  
  If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud bolt.
INSTALL FRONT STABILIZER LINK ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
CONNECT TIE ROD END SUB-ASSEMBLY LH
1. Connect the tie rod end sub-assembly LH to the steering knuckle with the nut.
  
  Torque:
  
  49 N*m { 500 kgf*cm, 36 ft.*lbf }
  
  Note
  
  Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.
2. Install a new cotter pin.
CONNECT TIE ROD END SUB-ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
INSTALL FRONT SPEED SENSOR LH
1. Install the front speed sensor and front flexible hose to the front shock absorber with the bolt and clamp.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
  
  Note
  
  Do not twist the front speed sensor when installing it.
  
  Tech Tips
  
  Install the front front flexible hose first and then the speed sensor harness bracket.
INSTALL FRONT SPEED SENSOR RH

Tech Tips

Perform the same procedure as for the LH side.
INSTALL FRONT AXLE SHAFT NUT LH
1. Using a chisel and a hammer, stake the front axle shaft nut.
INSTALL FRONT AXLE SHAFT NUT RH

Tech Tips

Perform the same procedure as for the LH side.

Text in Illustration
*1	Knock Pin

Text in Illustration
*a	Front Side

INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/ Exhaust Heat Recirculation System)

Note

When installing the water hose, ensure that the exhaust heat recirculation system is filled with coolant. Otherwise, the engine water pump assembly may be damaged.

Using a vernier caliper, measure the free length of the compression springs.

Minimum (front) 41.5 mm (1.64 in.)

Minimum (rear) 38.5 mm (1.52 in.)

Tech Tips

If the free length is less than minimum, replace the compression spring.
Fully insert 2 new gaskets to the exhaust manifold and front exhaust pipe assembly.

Text in Illustration
*1	Exhaust Manifold and Front Exhaust Pipe Assembly
*2	Gasket
*3	Wooden Block

Using a plastic hammer and wooden block, tap in each new gasket until its surface is flush with the exhaust manifold and front exhaust pipe assembly.

Note

Be careful with the installation direction of the gaskets.
Do not reuse the gaskets.
Do not damage the gaskets.
Do not push in the gasket by using the exhaust pipe when connecting it.

Connect the front exhaust pipe assembly to the 3 exhaust pipe supports.
Install the front exhaust pipe assembly with the 4 bolts and 4 compression springs.

Torque:

43 N*m { 440 kgf*cm, 32 ft.*lbf }
Connect the 2 heater water hoses.
Connect the 3 clamps and oxygen sensor connector.

INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/o Exhaust Heat Recirculation System)

Using a vernier caliper, measure the free length of the compression springs.

Minimum (front) 41.5 mm (1.64 in.)

Minimum (rear) 38.5 mm (1.52 in.)

Tech Tips

If the free length is less than minimum, replace the compression spring.
Fully insert 2 new gaskets to the exhaust manifold and front exhaust pipe assembly.

Text in Illustration
*1	Exhaust Manifold and Front Exhaust Pipe Assembly
*2	Gasket
*3	Wooden Block

Using a plastic hammer and wooden block, tap in each new gasket until its surface is flush with the exhaust manifold and front exhaust pipe assembly.

Note

Be careful with the installation direction of the gaskets.
Do not reuse the gaskets.
Do not damage the gaskets.
Do not push in the gasket by using the exhaust pipe when connecting it.

Connect the front exhaust pipe assembly to the 3 exhaust pipe supports.
Install the front exhaust pipe assembly with the 4 bolts and 4 compression springs.

Torque:

43 N*m { 440 kgf*cm, 32 ft.*lbf }

INSTALL FRONT CENTER FLOOR BRACE
1. Install the front center floor brace with the 4 bolts.
  
  Torque:
  
  51 N*m { 520 kgf*cm, 38 ft.*lbf }
INSTALL NO. 2 ENGINE UNDER COVER
1. Install the No. 2 engine under cover with the 4 clips.

CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

Text in Illustration
*1	Clip A
*2	Clip B
*a	Lip

Place clip A as shown in the illustration and engage clip B to the body to connect the No. 1 steering column hole cover sub-assembly.

Note

Make sure that the lips of the No. 1 steering column hole cover sub-assembly are not damaged.

CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
1. Text in Illustration
  
  *1 Matchmark
  
  Align the matchmarks on the No. 2 steering intermediate shaft assembly and the steering intermediate shaft assembly.
2. Install the bolt.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
INSTALL COLUMN HOLE COVER SILENCER SHEET
1. Install the column hole cover silencer sheet with the 2 clips.
2. Install the floor carpet.
INSTALL ENGINE WIRE
1. Connect the 12 wire harness clamps and 6 connectors and install the 2 bolts.
  
  Torque:
  
  8.4 N*m { 86 kgf*cm, 74 in.*lbf }
2. Connect the wire harness with the 2 clamps.
3. Text in Illustration
  
  *1 Green-colored Lock
  
  Connect the connector and lock the green-colored lock as shown in the illustration.
  
  CAUTION:
  
  Wear insulated gloves when performing the procedure.
4. Connect the wire harness with the 2 clamps.
5. Connect the wire harness 2 clamps to the engine room junction block.
6. Connect the 2 connectors to the engine room junction block.
7. Connect the connector to the ECM with the 2 clamps and lock lever.
CONNECT NO. 5 INVERTER COOLING HOSE
1. Connect the No. 5 inverter cooling hose with the clamp.
CONNECT NO. 3 INVERTER COOLING HOSE
1. Connect the No. 3 inverter cooling hose with the clamp.
INSTALL RADIATOR PIPE
1. Install the radiator pipe with the 2 bolts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
2. Install the No. 3 radiator hose with the clamp.
CONNECT NO. 4 WATER BY-PASS HOSE
1. Connect the No. 4 water by-pass hose with the clamp.
CONNECT NO. 1 RADIATOR HOSE
1. Connect the No. 1 radiator hose with the clamp.
INSTALL INVERTER TRAY BRACKET
1. 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 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.
INSTALL INVERTER RESERVE TANK ASSEMBLY
1. Temporarily install bolt A to the inverter reserve tank assembly.
2. Tighten the 2 bolts to the inverter reserve tank assembly in the order bolt B and bolt A.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL INVERTER WITH CONVERTER ASSEMBLY
CAUTION:

Wear insulating gloves.
1. 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 }
CONNECT WATER HOSE
1. 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. 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.
CONNECT NO. 2 ENGINE ROOM WIRE
1. Disconnect the No. 2 engine room wire from the protector.
2. 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. Install the No. 1 relay block cover and 2 clamps.
4. Install the relay block cover.
REMOVE INVERTER TERMINAL COVER
CAUTION:

Wear insulating gloves.
1. 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.
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. Temporarily install the No. 2 engine wire (high voltage cables of the air conditioning) and 4 bolts to the inverter assembly by hand.
2. Fully tighten the 4 bolts.
  
  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.
3. Connect the harness clamp.
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. Temporarily install the high voltage cable of the motor (MG2) and 5 bolts to the inverter assembly by hand.
2. Fully tighten the 5 bolts.
  
  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.
3. Connect the harness clamp.
4. Temporarily install the high voltage cable of the generator (MG1) and 5 bolts to the inverter assembly by hand.
5. Fully tighten the 5 bolts.
  
  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.
6. Text in Illustration
  
  *1 Align Mark
  
  Install the cable and cover.
  
  Note
  
  Close the cover so that the matchmarks are not visible.

Text in Illustration
*1	Matchmark

Text in Illustration
*1	Green-colored Lock

Text in Illustration
*1	Align Mark

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.

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

Temporarily install the frame wire (high voltage cables of the hybrid battery) and 4 bolts to the inverter assembly by hand.

Fully tighten the 4 bolts.

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 are fully engaged.
Connect the harness clamp.

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. Check that each connector and terminal is firmly installed.
  
  Note
  
  Make sure that the bolts are fully tightened.
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. 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 }
CONNECT 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. Install the bolt, clamp and clip, and connect the engine room main wire.
  
  Torque:
  
  8.3 N*m { 85 kgf*cm, 73 in.*lbf }
2. Install the bolt.
  
  Torque:
  
  8.3 N*m { 85 kgf*cm, 73 in.*lbf }
3. Connect the engine wire to the engine room main wire.
4. Connect the connector to the inverter with converter assembly and lock the connector with the lock lever.
INSTALL NO. 1 INVERTER BRACKET
1. 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 { 138 kgf*cm, 10 ft.*lbf }
INSTALL AIR CLEANER CASE
1. Install the air cleaner case with the 3 bolts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
2. Connect the No. 4 water by-pass hose to the air cleaner case with the 3 clamps.
3. Install the air cleaner filter element.
INSTALL INLET AIR CLEANER ASSEMBLY
1. Install the inlet air cleaner assembly with the 3 bolts.
  
  Torque:
  
  7.0 N*m { 71 kgf*cm, 62 in.*lbf }
2. Connect the No. 4 water by-pass hose to the inlet air cleaner assembly with the clamp.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
1. Install the air cleaner cap sub-assembly with the 2 clamps and hose band.
2. Connect the air flow meter connector.
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.
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.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
INSTALL BATTERY BOX COVER
1. Engage the 3 guides to install the battery box cover.
INSTALL REAR DECK FLOOR BOX
1. Install the rear deck floor box.
INSTALL REAR FLOOR MAT
1. Install the rear floor mat.
ADD HYBRID TRANSAXLE FLUID
1. Text in Illustration
  
  *1 Filler nozzle
  
  Add transaxle fluid until the fluid level is between 0 to 10 mm (0 to 0.394 in.) from the bottom lip of the filler plug opening.
  Note
  - Stop the vehicle on a level surface.
  - Recheck the transaxle fluid level after driving following fluid replacement.
  - Insufficient or excessive amounts of transaxle fluid may damage the hybrid transaxle.
  - Be sure to add fluid slowly. If fluid is added quickly, the fluid may hit internal parts and bounce back, resulting in fluid coming out of the filler plug opening.
  - Be sure to fully insert the filler nozzle into the filler plug opening.
  Reference
  
  3.4 liters (3.6 US qts, 3.0 lmp.qts)
  
  Fluid Type
  
  Toyota Genuine ATF WS

Text in Illustration
*1	Interlock

Text in Illustration
*1	Filler nozzle

Reference
3.4 liters (3.6 US qts, 3.0 lmp.qts)

Fluid Type
Toyota Genuine ATF WS

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 No.	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

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.)

Coolant quantity
2.1 liters (2.2 US qts, 1.8 Imp. qts.)

When using the intelligent tester:

Connect the intelligent tester to the DLC3.
Turn the power switch on (IG).
Enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

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 inverter water pump assembly becomes smaller and the circulation of coolant in the reserve tank improves.

Tech Tips

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

When not using the intelligent tester:

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

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 inverter water pump assembly becomes smaller and the circulation of coolant in the reserve tank improves.

Tech Tips

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

After the air is completely bled from the cooling system, tighten the reserve tank cap.
Add coolant to the F line of the reserve tank.

ADD COOLANT (for Engine)

Tighten the radiator drain cock plug.
Connect the hose to the air release valve. (w/ Air Release Valve)
Loosen the air release valve. (w/ Air Release Valve)
Add TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank filler opening until coolant overflows from the air release valve. Then tighten the air release valve. (w/ Air Release Valve)
Disconnect the hose from the air release valve. (w/ Air Release Valve)

Text in Illustration
*1	B Line

Add TOYOTA Super Long Life Coolant (SLLC) to the B line on 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.

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.
Put the engine in inspection mode Click here.
Install the reservoir tank cap.
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 the 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.
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 lines.

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

INSPECT HYBRID TRANSAXLE FLUID
1. After adding fluid, leave it for 30 seconds so that the fluid surface can become still again, and then check that the fluid level is between 0 to 10 mm (0 to 0.394 in.) from the bottom lip of the filler plug opening. (If the fluid is insufficient, return to the Add Hybrid Transaxle Fluid procedure.)
  Note
  
  Stop the vehicle on a level surface.
  
  Recheck the transaxle fluid level after driving following fluid replacement.
  
  Insufficient or excessive amounts of transaxle fluid may damage the hybrid transaxle.
  
  Be sure to add fluid slowly. If fluid is added quickly, the fluid may hit internal parts and bounce back, resulting in fluid coming out of the filler plug opening.
  
  Be sure to directly check that the transaxle fluid level is within the specified range.
2. Check for leaks if the quantity of transaxle fluid is low.
3. Using a 10 mm hexagon socket wrench, install the filler plug with a new gasket.
  
  Torque:
  
  50 N*m { 510 kgf*cm, 37 ft.*lbf }
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. 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, inverter water pump assembly, inverter with converter, and hybrid vehicle transaxle assembly for leaks.
4. Reinstall the reserve tank cap.
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. 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 a radiator 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.
INSPECT FOR EXHAUST GAS LEAK
INSTALL CENTER NO. 4 ENGINE UNDER COVER
INSTALL NO. 1 ENGINE UNDER COVER
INSTALL ENGINE UNDER COVER
INSTALL REAR ENGINE UNDER COVER LH
INSTALL REAR ENGINE UNDER COVER RH
INSTALL FRONT WHEELS

Torque:

103 N*m { 1050 kgf*cm, 76 ft.*lbf }
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Click here
INSTALL NO. 2 CYLINDER HEAD COVER
1. Engage the 3 clips to install the cover.
  Note
  - Be sure to engage the clips securely.
  - Do not apply excessive force or hit the cover to engage the clips. This may cause the cover to break.
INSTALL HOOD SUB-ASSEMBLY
1. Install the hood sub-assembly with the 4 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
2. Connect the 3 clamps and washer hose.
INSTALL HOOD INSULATOR
1. Install the hood insulator with the 6 clips.

Text in Illustration
*1	Full Line
*2	Low Line

INSPECT HOOD SUB-ASSEMBLY

Check that the clearance measurements of areas A through F are within each standard range.

Standard Clearance

Area	Measurement	Area	Measurement
A	3.1 to 6.1 mm (0.122 to 0.240 in.)	D	-1.4 to 1.6 mm (-0.0551 to 0.0630 in.)
B	-1.5 to 1.5 mm (-0.0591 to 0.0591 in.)	E	2.3 to 5.3 mm (0.0906 to 0.209 in.)
C	1.7 to 4.7 mm (0.0669 to 0.185 in.)	F	-1.0 to 1.0 mm (-0.0394 to 0.0394 in.)

ADJUST HOOD SUB-ASSEMBLY
1. Horizontally and vertically adjust the hood.
  1. Loosen the 4 hinge bolts of the hood.
  2. Adjust the clearance between the hood and front fender by moving the hood.
  3. Tighten the 4 hinge bolts after the adjustment.
    
    Torque:
    
    13 N*m { 133 kgf*cm, 10 ft.*lbf }
2. Adjust the height of the front end of the hood using the cushion rubber.
  1. Adjust the 2 cushion rubbers so that the heights of the hood and fender are aligned.
    
    Tech Tips
    
    Raise or lower the front end of the hood by turning the cushion rubber.
3. Adjust the hood lock.
  1. Loosen the 3 bolts.
  2. Tighten the bolts after the adjustment.
    
    Torque:
    
    7.5 N*m { 77 kgf*cm, 66 in.*lbf }
  3. Check that the striker can engage with the hood lock smoothly.

INSTALL OUTER COWL TOP PANEL (for LHD)

Install the outer cowl top panel with the 8 bolts and nut.

Torque:

Bolt

8.8 N*m { 90 kgf*cm, 78 in.*lbf }

Nut

12 N*m { 122 kgf*cm, 9 ft.*lbf }
Engage the clamp.

Text in Illustration
*1	No. 1 Heater Air Duct Splash Shield Seal
*2	Water Guard Plate RH

Bend the No. 1 heater air duct splash shield seal and water guard plate RH, and engage each claw.

INSTALL OUTER COWL TOP PANEL (for RHD)

Install the outer cowl top panel with the 8 bolts and nut.

Torque:

Bolt

8.8 N*m { 90 kgf*cm, 78 in.*lbf }

Nut

12 N*m { 122 kgf*cm, 9 ft.*lbf }
Engage the clamp of the wire harness.

Text in Illustration
*1	Water Guard Plate RH
*2	No. 1 Heater Air Duct Splash Shield Seal

Bend the water guard plate RH and No. 1 heater air duct splash shield seal, and engage each claw.

INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for LHD)
1. Install the cowl body mounting reinforcement LH with the 3 bolts.
  
  Torque:
  
  8.8 N*m { 90 kgf*cm, 78 in.*lbf }
INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for RHD)
1. Install the cowl body mounting reinforcement LH with the 3 bolts.
  
  Torque:
  
  8.8 N*m { 90 kgf*cm, 73 in.*lbf }
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
1. Install the windshield wiper motor and link assembly with the 2 bolts.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
2. Connect the connector.
INSTALL COWL TOP VENTILATOR LOUVER LH
1. Engage the clip and 6 claws, and install the cowl top ventilator louver LH.
INSTALL COWL TOP VENTILATOR LOUVER RH
1. Engage the clip and 11 claws, and install the cowl top ventilator louver RH.
INSTALL HOOD TO COWL TOP SEAL
1. Engage the 7 clips and install the hood to cowl top seal.

INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

Operate the wiper and stop the windshield wiper motor at the automatic stop position.

Text in Illustration
*1	Wiper Arm Serration
*2	Wire Brush
*3	Wiper Pivot Serration

When reusing the front wiper arm and blade assembly RH:

Clean the wiper arm serrations.

When reusing the windshield wiper link assembly:
1. Clean the wiper pivot serrations with a wire brush.
Text in Illustration

*1 Louver Edge

*2 Ceramic Notch

Install the front wiper arm and blade assembly RH with the nut to the position shown in the illustration.

Torque:

26 N*m { 265 kgf*cm, 19 ft.*lbf }

Tech Tips

Hold the arm hinge by hand to fasten the nut.

Area Measurement

A 17.5 to 32.5 mm (0.69 to 1.28 in.)

Text in Illustration
*1	Louver Edge
*2	Ceramic Notch

Area	Measurement
A	17.5 to 32.5 mm (0.69 to 1.28 in.)

INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

Operate the wiper and stop the windshield wiper motor at the automatic stop position.

Text in Illustration
*1	Wiper Arm Serration
*2	Wire Brush
*3	Wiper Pivot Serration

When reusing the front wiper arm and blade assembly LH:

Clean the wiper arm serrations.

When reusing the windshield wiper link assembly:
1. Clean the wiper pivot serrations with a wire brush.
Text in Illustration

*1 Louver Edge

*2 Ceramic Notch

Install the front wiper arm and blade assembly LH with the nut to the position shown in the illustration.

Torque:

26 N*m { 265 kgf*cm, 19 ft.*lbf }

Tech Tips

Hold the arm hinge by hand to fasten the nut.

Area Measurement

A 25.5 to 40.5 mm (1.00 to 1.59 in.)
Operate the front wipers while spraying washer fluid on the windshield glass. Make sure that the front wipers function properly and the wipers do not come into contact with the vehicle body.

INSTALL FRONT WIPER ARM HEAD CAP
1. Install the 2 front wiper arm head caps.
CHECK ABS SPEED SENSOR SIGNAL

Click here

Minimum (front)	41.5 mm (1.64 in.)
Minimum (rear)	38.5 mm (1.52 in.)