GENERATOR CABLE INSTALLATION

INSTALL GENERATOR CABLE
Note

Wear insulated gloves.
1. 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. 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. 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. Connect the generator cable clamp to the motor cable bracket.
INSTALL RADIATOR PIPE
1. 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.
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	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 }
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. 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 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.

Text in Illustration
*1	Interlock

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 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.
INSTALL NO. 1 ENGINE UNDER COVER
INSTALL ENGINE UNDER COVER

Text in Illustration
*1	Full Line
*2	Low Line