FRAME WIRE INSTALLATION

INSTALL FRAME WIRE

CAUTION:

Wear insulating gloves.

Note

Insulate the removed terminals with insulating tape.
1. Install the frame wire with the 4 clamps.
2. Text in Illustration
  
  *a Front Side
  
  Insert the frame wire into the floor panel hole.
  
  Tech Tips
  
  The arrow should point toward the front of the vehicle.
3. Install the nut.
  
  Torque:
  
  8.4 N*m { 85 kgf*cm, 74 in.*lbf }
4. Install the nut and clamp.
  
  Torque:
  
  8.4 N*m { 85 kgf*cm, 74 in.*lbf }
5. Install the nut and 2 clamps.
  
  Torque:
  
  8.4 N*m { 85 kgf*cm, 74 in.*lbf }
6. Install the heater water pipe sub-assembly with the nut.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
7. Connect the 4 clamps.
8. Connect the connector to the engine room junction block assembly.
9. Connect the 2 wire harness clamps to the floor panel.
10. Install the wire harness protector and connect the clamp to the floor panel.
INSTALL INVERTER RESERVE TANK ASSEMBLY (for 2ZR-FXE)
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 RESERVE TANK ASSEMBLY (for 5ZR-FXE)
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 }
CONNECT HYBRID BATTERY JUNCTION BLOCK ASSEMBLY

CAUTION:

Wear insulating gloves.
1. Install the frame wire on the hybrid battery junction block assembly with the 2 nuts.
  
  Torque:
  
  9.0 N*m { 92 kgf*cm, 80 in.*lbf }
2. Connect the clamp and frame wire.
  Note
  - Make sure that the ends of the frame wire are not crossed over each other.
  - Be sure to connect the ends of the frame wire to the connect terminals.
CHECK HIGH VOLTAGE CABLE CONNECTION CONDITION
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.
CONNECT CABLE TO AUXILIARY BATTERY TERMINAL
1. Connect the 4 wire harness clamps.
2. Connect the clamp.
3. Install the nut, and connect the clamp.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
4. Install the terminal cover.
INSTALL UPPER HYBRID BATTERY COVER SUB-ASSEMBLY

CAUTION:

Be sure to wear insulated gloves and protective goggles.

Tech Tips

Perform this procedure only when removal and installation of any parts under the upper hybrid battery cover sub-assembly is necessary.
1. Install the upper hybrid battery cover sub-assembly and No. 1 hybrid battery shield sub-assembly with the 3 bolts and 8 nuts.
  
  Torque:
  
  7.5 N*m { 76 kgf*cm, 66 in.*lbf }
INSTALL NO. 1 HYBRID BATTERY EXHAUST DUCT
1. Insert the No. 1 hybrid battery exhaust duct with the clip.
  
  Note
  
  Ensure that the duct is installed securely.
INSTALL NO. 1 HYBRID BATTERY INTAKE DUCT

Note

Ensure that the duct is installed securely.
1. Install the No. 1 hybrid battery intake duct with the 2 clips.
INSTALL REAR FLOOR BOARD SPACER
1. Install the rear floor board spacer with the 2 clips.

Text in Illustration
*a	Front Side

INSTALL HV BATTERY SHIELD SHEET

Text in Illustration
*a	Tab
*b	Edge
*c	Installation position

Align the edge of the tab of a new hybrid vehicle battery shield sheet with the edge of the hybrid battery cover sub-assembly, and then install the hybrid vehicle battery shield sheet with the double-sided tape.

Text in Illustration

*a Installation position

Overlap the hybrid vehicle battery shield sheet with the hybrid battery cover sheet, fold the edge as shown in the illustration, and secure it with the double-sided tape.

INSTALL REAR NO. 1 FLOOR BOARD
1. Engage the 2 claws and 2 clips.
2. Install the rear No. 1 floor board with the bolt.
INSTALL REAR NO. 2 FLOOR BOARD SUB-ASSEMBLY
1. Engage the claw and 2 clips to install the rear No. 2 floor board sub-assembly.
INSTALL REAR NO. 1 FLOOR BOARD SUB-ASSEMBLY
1. Engage the 2 claws and 2 clips to install the rear No. 1 floor board sub-assembly.
INSTALL REAR SEAT SIDE GARNISH RH

Tech Tips

Use the same procedure described for the LH side Click here.
INSTALL REAR DOOR SCUFF PLATE RH

Tech Tips

Use the same procedure described for the LH side Click here.
INSTALL REAR SEATBACK ASSEMBLY RH

Click here
INSTALL FRONT SUSPENSION MEMBER BRACE REAR RH
1. Install the front suspension member brace rear RH with the 3 bolts.
  
  Torque:
  
  Bolt A
  
  137 N*m { 1397 kgf*cm, 101 ft.*lbf }
  
  Bolt B
  
  93 N*m { 948 kgf*cm, 69 ft.*lbf }
INSTALL FRONT CENTER FLOOR COVER RH (w/ Cover)
1. Install the front center floor cover RH with the 3 clips.
INSTALL FRONT FLOOR COVER RH (w/ Cover)
1. Install the front floor cover RH with the 4 clips.
2. Install the bolt
INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR
1. Install the No. 1 front floor heat insulator with the 3 nuts.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 2ZR-FXE)

Click here
INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 5ZR-FXE)

Click here
INSTALL INVERTER WITH CONVERTER ASSEMBLY

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INSTALL DECK FLOOR BOX LH (w/o Woofer)
1. Engage the 6 guides.
2. Install the deck floor box LH with the clip.
INSTALL REAR NO. 4 FLOOR BOARD (w/ Woofer)
1. Engage the 2 clips and 3 guides to install the rear No. 4 floor board.
INSTALL REAR NO. 4 FLOOR BOARD (w/o Woofer)
1. Install the rear No. 4 floor board.
INSTALL TONNEAU COVER ASSEMBLY (w/ Tonneau Cover)
1. Install the tonneau cover assembly.
INSTALL SERVICE PLUG GRIP

Click here