ENGINE ASSEMBLY INSTALLATION

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 }

INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH

INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

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 FRONT DRIVE SHAFT HOLE SNAP RING LH

1. Install a new front drive shaft hole snap ring to the front drive inboard joint assembly.

   Note

   Face the end gap of the front drive inboard joint hole snap ring downward.

INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

1. Install the front lower No. 1 suspension arm sub-assembly to the front lower ball joint assembly with the bolt and 2 nuts.

   Torque:

   89 N*m  { 908 kgf*cm, 66 ft.*lbf }

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.

CONNECT TIE ROD END SUB-ASSEMBLY LH

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:

   19 N*m  { 192 kgf*cm, 14 ft.*lbf }

   Note

   Do not twist the front speed sensor when installing it.

   Tech Tips

   Install the front flexible hose first and then the speed sensor harness bracket.

2. Install the front speed sensor to the steering knuckle with the bolt.

   Torque:

   8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

   Note

   Do not twist the front speed sensor when installing it.

INSTALL FRONT AXLE SHAFT NUT LH

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

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

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 FRONT NO. 3 ENGINE UNDER COVER

1. Install the front No. 3 engine under cover with the 4 clips.

CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

1. 

   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 lip of the No. 1 steering column hole cover sub-assembly is not damaged.

CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

1. 

   Text in Illustration

   *a

   Matchmark

   Align the matchmarks on the No. 2 steering intermediate shaft assembly and steering intermediate shaft to connect the No. 2 steering intermediate shaft assembly to the steering intermediate shaft.

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 ELECTRIC INVERTER COMPRESSOR

INSTALL INVERTER WITH CONVERTER ASSEMBLY

CONNECT WATER HOSE

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 COVER

1. Remove the 9 bolts and inverter cover.

   Note

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

CONNECT NO. 2 ENGINE WIRE

CONNECT MOTOR CABLE

CONNECT GENERATOR CABLE

CONNECT FRAME WIRE

1. 

   Text in Illustration

   *1	Interlock
   *2	High voltage cables of the hybrid battery
   *a	Front view of frame wire connector

   Temporarily install the frame wire (high voltage cables of the hybrid battery) 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.

   • Make sure that the interlock are fully engaged.

3. Connect the 2 harness clamps.

CHECK HIGH VOLTAGE CABLE CONNECTION

INSTALL INVERTER COVER

1. 

   Text in Illustration

   *1

   Interlock

   Install the inverter 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

INSTALL NO. 1 INVERTER BRACKET

INSTALL AIR CLEANER HOSE ASSEMBLY

1. Install the air cleaner hose assembly to the throttle body assembly and tighten the hose clamp.

2. Connect the ventilation hose to the cylinder head cover sub-assembly.

INSTALL SERVICE PLUG GRIP

INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE

1. Engage the 4 claws and 2 guides to install the rear floor board upper No. 3 plate.

INSTALL DECK FLOOR BOX RH

1. Engage the 6 guides.

2. Install the deck floor box RH with the clip.

INSTALL REAR NO. 3 FLOOR BOARD

1. Install the rear No. 3 floor board.

INSTALL REAR DECK FLOOR BOX

1. Install the rear deck floor box.

INSTALL REAR NO. 2 FLOOR BOARD

1. Install the rear No. 2 floor board.

ADD HYBRID TRANSAXLE FLUID

1. 

   Text in Illustration

   *1	Filler Plug
   *2	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.

   • Use Toyota Genuine ATF WS.

   • Be sure to fully insert the filler nozzle into the filler plug opening.

   • 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.

   • Insufficient or excessive amounts of transaxle fluid may damage the hybrid transaxle.

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

2. 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 level is too low, return to the Add Hybrid Transaxle Fluid procedure.)

   Note

   After adding fluid, make sure to check the fluid level.

INSPECT HYBRID TRANSAXLE FLUID

1. 

   Text in Illustration

   *1	Filler Plug

   Using a 10 mm hexagon socket wrench, remove the filler plug and gasket.

2. 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 level is too low, return to the Add Hybrid Transaxle Fluid procedure.)

   Note

   
   

   • Stop the vehicle on a level surface.

   • Be sure to directly check that the transaxle fluid level is within the specified range.

   • Insufficient or excessive amounts of transaxle fluid may damage the hybrid transaxle.

   • If the fluid was replaced or fluid was added, make sure to recheck the fluid level after driving the vehicle.

3. Check for leaks if the quantity of transaxle fluid is low.

4. 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 }

ADD COOLANT (for Engine)

1. Tighten the radiator drain cock plug.

2. 

   Text in Illustration

   *1

   B Line

   Add coolant to B line of the reserve tank.

   Standard Capacity
   Item Capacity Engine coolant w/ Exhaust Heat Recirculation System: 6.9 liters (7.3 US qts, 6.1 lmp. qts) w/o Exhaust Heat Recirculation System: 6.5 liters (6.9 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.

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

   If the coolant level is low, add coolant.

4. Put the engine in inspection mode Click here.

5. Install the reserve tank cap.

6. 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. (●1)

      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 fans.

   2. Stop the engine and wait until the coolant cools down. Then if the coolant level is below the low line, add coolant so that the level will be between the full and low lines. (●2)

   3. Repeat the steps from (●1) to (●2) until the coolant level of the reserve tank remains above the low line.

7. 

   Text in Illustration

   *1	Full Line
   *2	Low Line

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

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

ADD COOLANT (for Inverter)

ADD ENGINE OIL

1. Add new engine oil and install the oil filler cap.

   Standard Oil Grade

   Oil Grade	Oil Viscosity (SAE)
   API grade SL "energy-conserving", SM "energy-conserving", SN "resource-conserving" or ILSAC multigrade engine oil	0W-20 5W-20 5W-30 10W-30
   API grade SL, SM or SN multigrade engine oil	15W-40 20W-50

   Standard Capacity

   Item	Standard Condition
   Drain and refill with oil filter change	4.2 liters (4.4 US qts, 3.7 lmp. qts)
   Drain and refill without oil filter change	3.9 liters (4.1 US qts, 3.4 lmp. qts)
   Dry fill	4.7 liters (5.0 US qts, 4.1 lmp. qts)

INSPECT ENGINE OIL LEVEL

1. Put the engine in inspection mode Click here.

2. Warm up and stop the engine, then wait for 5 minutes. The oil level should be between the low and full level marks on the engine oil level dipstick. If the engine oil level is low, check for leaks and add oil up to the full level mark.

   Note

   Do not fill with engine oil to above the full level mark.

INSPECT FOR FUEL LEAK

1. Check fuel pump operation.

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Turn the power switch on (IG).

      Note

      Do not start the engine.

   3. Turn the intelligent tester on.

   4. Enter the following menus: Powertrain / Engine and ECT / Active Test / Control the Fuel Pump / Speed.

   5. Check for pressure in the fuel inlet tube from the fuel line. Check that sounds of fuel flowing from the fuel tank can be heard. If no sounds can be heard, check the integration relay, fuel pump, ECM and wiring connectors.

2. Inspect for fuel leaks.

   
   

   1. Check that there are no fuel leaks after performing maintenance anywhere on the fuel system. If there are fuel leaks, repair or replace parts as necessary.

3. Turn the power switch off.

4. Disconnect the intelligent tester from the DLC3.

INSPECT FOR COOLANT LEAK (for Engine)

INSPECT FOR COOLANT LEAK (for Inverter)

INSPECT IGNITION TIMING

INSPECT ENGINE IDLE SPEED

1. Put the engine in inspection mode Click here.

2. Warm up and stop the engine.

3. When using the intelligent tester:

   
   

   1. Connect the intelligent tester to the DLC3.

   2. Put the engine in inspection mode Click here.

   3. Turn the intelligent tester on.

   4. Enter the following menus: Powertrain / Engine and ECT / Data List / Engine Speed.

      Tech Tips

      Refer to the intelligent tester operator's manual for further details.

   5. Inspect the engine idle speed.

      Standard idle speed
      950 to 1050 rpm

      Note

      
      

      • Turn all electrical systems and the A/C off.

      • Inspect the idle speed with the cooling fans off.

      • When checking the idle speed, the shift position neutral (N) or park (P) should be selected.

   6. Turn the power switch off.

   7. Turn the intelligent tester off.

   8. Disconnect the intelligent tester from the DLC3.

4. When not using the intelligent tester:

   
   
   1. 

      Text in Illustration

      *1

      DLC3

      Using SST, connect a tachometer tester probe to terminal 9 (TAC) of the DLC3.

      SST

      09843-18030

   2. Put the engine in inspection mode Click here.

   3. Inspect the engine idle speed.

      Standard idle speed
      950 to 1050 rpm

      Note

      
      

      • Turn all electrical systems and the A/C off.

      • Inspect the idle speed with the cooling fans off.

      • When checking the idle speed, the shift position neutral (N) or park (P) should be selected.

   4. Disconnect terminal 9 (TAC) of the DLC3.

INSPECT CO/HC

1. Put the engine in inspection mode Click here.

2. Warm up the engine.

3. Run the engine at 2500 rpm for approximately 180 seconds.

4. Insert a CO/HC meter testing probe at least 40 cm (1.31 ft.) into the tailpipe while idling.

5. Check the CO/HC concentration while idling and when the engine is running at 2500 rpm.

   Tech Tips

   When doing a 2 mode (with the engine idling/ running at 2500 rpm) test, the measurement procedures are determined by applicable local regulations.

   If the CO/HC concentration does not comply with the regulations, troubleshoot in the order given below.

   
   

   1. Check the DTCs.

      w/ EGR System: Click here.

      w/o EGR System: Click here.

   2. See the table below for possible causes, then inspect the applicable parts and repair them if necessary.

      CO	HC	Problem	Possible Cause
      Normal	High	Rough idle	Faulty ignition: Incorrect timing Fouled, shorted or improperly gapped plugs Incorrect valve clearance Leaks from intake and exhaust valves Leaks from cylinders Faulty EGR
      Low	High	Rough idle (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body Brake booster line Lean mixture causing misfire Faulty EGR
      High	High	Rough idle (Black smoke from exhaust)	Restricted air cleaner filter element sub-assembly Plugged PCV valve Faulty EFI systems: Faulty pressure regulator Faulty engine coolant temperature sensor Faulty mass air flow meter Faulty ECM Faulty injectors Throttle body Faulty EGR

INSTALL INVERTER COVER ASSEMBLY LH (w/ Cover)

1. Engage the claw and install the inverter cover assembly LH.

2. Install the 2 clips.

INSTALL RADIATOR SUPPORT OPENING COVER

1. Install the radiator support opening cover with the 9 clips (for 9 Clip Type).

2. Install the radiator support opening cover with the 7 clips (for 7 Clip Type).