HYBRID VEHICLE TRANSAXLE INSTALLATION


  1. INSTALL MOTOR CABLE BRACKET


    1. Install the motor cable bracket with the bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  2. 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 }

  3. INSTALL REAR ENGINE MOUNTING BRACKET


    1. A003VG1E01

      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.

  4. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. A003Y6UE01

      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.

  5. SUPPORT HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. Support the hybrid vehicle transaxle assembly with a transmission jack.

  6. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. A003ZF1E01
      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.

  7. INSTALL ENGINE MOUNTING BRACKET LH


    1. A003VE1E01

      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.

  8. INSTALL REAR ENGINE MOUNTING INSULATOR (for 2ZR-FXE)


    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.

  9. INSTALL REAR ENGINE MOUNTING INSULATOR (for 5ZR-FXE)


    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.

  10. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. Support the front suspension crossmember sub-assembly with an engine lifter using 4 attachments or equivalent tools.

      Note


      • Make sure to secure the front suspension crossmember sub-assembly to prevent it from dropping.

      • Use the attachments to keep the front suspension crossmember sub-assembly level.

      • The front suspension crossmember sub-assembly is a heavy component. Make sure that it is supported securely.

    2. Tighten the bolts on the left and right sides while alternately inserting SST into the left and right side reference holes in the front suspension crossmember sub-assembly.

      A003V3OE01
      Text in Illustration
      *1 Front - -
      *a OK *b NG
      SST
      09670-00020
      Torque:
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }

    3. Lower the engine lifter.

    4. Install the rear engine mounting insulator with bolts A and B, and nuts C and D by tightening them in several steps.

      A003VF7E01
      Torque:
      Bolt A, B, Nut C, D
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

      Temporarily tighten bolt A, and then fully tighten the 2 bolts and 2 nuts in the order of B, D, C, and A.

    5. Install the 2 wiring harness clamp brackets with the 2 bolts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

  11. INSTALL FRONT ENGINE MOUNTING INSULATOR (for 2ZR-FXE)


    1. A003VPM

      Temporarily install the front engine mounting insulator with the bolt and nut.

  12. INSTALL FRONT ENGINE MOUNTING INSULATOR (for 5ZR-FXE)


    1. A003VPM

      Temporarily install the front engine mounting insulator with the bolt and nut.

  13. 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 }

  14. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH


    1. A003V95E02

      Install the front suspension member rear brace LH with the 3 bolts and clip.

      Torque:
      Bolt A
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
      Bolt B, C
      93 N*m  { 948 kgf*cm, 69 ft.*lbf }

      Note

      Temporarily tighten bolts A and B, and then fully tighten the 3 bolts in the order of C, B, and A.

  15. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  16. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH


    1. A003ZUTE01

      Install the rear side rail reinforcement sub-assembly 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.

  17. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  18. INSTALL FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT


    1. Install the front engine mounting bracket lower reinforcement with the 2 bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

  19. INSTALL FLYWHEEL HOUSING SIDE COVER


    1. Install the flywheel housing side cover.

  20. INSTALL STARTER HOLE INSULATOR


    1. Install the starter hole insulator with the 2 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  21. REMOVE ENGINE HANGERS


    1. Remove the 2 bolts and 2 engine hangers.

  22. 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.

  23. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH

    Tech Tips

    Perform the same procedure as for the LH side.

  24. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH


    1. A003YU0

      Align the inboard joint splines, and using a brass bar and a hammer, install the front drive shaft assembly.

      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.

      Tech Tips

      Confirm whether the drive shaft is securely driven in by checking the reaction force and sound.

    2. A003Y2VE02
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly.

  25. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  26. 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 }

  27. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  28. 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.

  29. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  30. CONNECT TIE ROD END SUB-ASSEMBLY LH


    1. A003Z1W

      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 clip are not aligned.

    2. Install a new clip.

  31. CONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  32. INSTALL FRONT SPEED SENSOR LH


    1. Install the front speed sensor and front flexible hose to the front shock absorber with coil spring 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.

  33. INSTALL FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  34. INSTALL FRONT AXLE SHAFT NUT LH


    1. Clean the threaded parts on the front drive shaft assembly and a new front axle shaft nut using a non-residue solvent.

      Tech Tips


      • Be sure to perform this work even when using a new drive shaft.

      • Keep the threaded parts free of oil and foreign matter.

    2. A003ZRD

      Using a socket wrench (30 mm), install the axle shaft nut.

      Torque:
      216 N*m  { 2203 kgf*cm, 159 ft.*lbf }

    3. Using a chisel and hammer, stake the front axle shaft nut.

  35. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  36. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 2ZR-FXE)

    w/ Exhaust Heat Recirculation System Click here

    w/o Exhaust Heat Recirculation System Click here

  37. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 5ZR-FXE)


    1. A003Z73

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

      Minimum 41.5 mm (1.64 in.)

      Tech Tips

      If the free length is less than minimum, replace the compression spring.

    2. Fully insert a new gasket to the exhaust manifold.

    3. A003WOME17
      Text in Illustration
      *1 Exhaust Manifold
      *2 Gasket
      *3 Wooden Block

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

      Note


      • Be careful with the installation direction of the gasket.

      • Do not reuse the gasket.

      • Do not damage the gasket.

      • Do not push in the gasket by using the exhaust pipe when connecting it.

    4. Connect the front exhaust pipe assembly to the 2exhaust pipe supports.

    5. A003X4N

      Install the front exhaust pipe assembly with the 2 bolts and 2 compression springs.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  38. INSTALL FRONT CENTER FLOOR BRACE (for 2ZR-FXE)


    1. Install the front center floor brace with the 4 bolts.

      Torque:
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }

  39. INSTALL FRONT CENTER FLOOR BRACE (for 5ZR-FXE)


    1. A003XBU

      Install the front center floor brace with the 4 bolts.

      Torque:
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }

  40. INSTALL FRONT NO. 3 ENGINE UNDER COVER (for 2ZR-FXE)


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

  41. INSTALL FRONT NO. 3 ENGINE UNDER COVER (for 5ZR-FXE)


    1. A003X24

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

  42. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY


    1. A003Y1LE05
      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.

  43. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A003YG6E01
      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 }

  44. INSTALL COLUMN HOLE COVER SILENCER SHEET


    1. Install the column hole cover silencer sheet with the 2 clips.

    2. Install the floor carpet.

  45. INSTALL WIRE HARNESS


    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. A003ZAUE01
      Text in Illustration
      *a 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.

    3. Connect the wire harness with the 2 clamps.

    4. Connect the wire harness 2 clamps to the engine room junction block.

    5. Connect the 2 connectors to the engine room junction block.

    6. Connect the connector to the ECM with the 2 clamps and lock lever.

  46. CONNECT NO. 5 INVERTER COOLING HOSE (for 2ZR-FXE)


    1. Connect the No. 5 inverter cooling hose with the clamp.

  47. REMOVE NO. 5 INVERTER COOLING HOSE (for 5ZR-FXE)


    1. Connect the No. 5 inverter cooling hose with the clamp.

  48. CONNECT NO. 3 INVERTER COOLING HOSE (for 2ZR-FXE)


    1. Connect the No. 3 inverter cooling hose with the clamp.

  49. CONNECT NO. 3 INVERTER COOLING HOSE (for 5ZR-FXE)


    1. Connect the No. 3 inverter cooling hose with the clamp.

  50. INSTALL RADIATOR PIPE (for 2ZR-FXE)


    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.

  51. INSTALL RADIATOR PIPE (for 5ZR-FXE)


    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.

  52. CONNECT NO. 4 WATER BY-PASS HOSE (for 2ZR-FXE)


    1. Connect the No. 4 water by-pass hose with the clamp.

  53. CONNECT NO. 4 WATER BY-PASS HOSE (for 5ZR-FXE)


    1. Connect the No. 4 water by-pass hose with the clamp.

  54. CONNECT NO. 1 RADIATOR HOSE (for 2ZR-FXE)


    1. Connect the No. 1 radiator hose with the clamp.

  55. CONNECT NO. 1 RADIATOR HOSE (for 5ZR-FXE)


    1. Connect the No. 1 radiator hose with the clamp.

  56. INSTALL INVERTER TRAY BRACKET (for 2ZR-FXE)


    1. A003XZQE01

      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.

  57. INSTALL INVERTER TRAY BRACKET (for 5ZR-FXE)


    1. A003XZQE01

      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.

  58. INSTALL INVERTER RESERVE TANK ASSEMBLY (for 2ZR-FXE)


    1. A003V8FE01

      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 }

  59. INSTALL INVERTER RESERVE TANK ASSEMBLY (for 5ZR-FXE)


    1. A003V8FE01

      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 }

  60. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A003WZ0E02

      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 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 }

  61. CONNECT WATER HOSE


    1. A003Z9JE01

      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. A003V7TE01

      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.

  62. 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.

  63. REMOVE INVERTER COVER

    CAUTION:

    Wear insulating gloves.


    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.

  64. 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. A003ZM2E01

      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.

  65. CONNECT MOTOR CABLE

    CAUTION:

    Wear insulating gloves.

    Note

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


    1. A003VLRE01

      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.

  66. CONNECT GENERATOR CABLE

    CAUTION:

    Wear insulating gloves.

    Note

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


    1. A003ZEQE01

      Temporarily install the high voltage cable of the generator cable (MG1) 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. A003V6NE02
      Text in Illustration
      *a Align Mark

      Install the generator cable and cover.

      Note

      Close the cover so that the matchmarks are not visible.

  67. 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. A003WPGE01
      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.

  68. 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. A003W5Y

      Check that each connector and terminal is firmly installed.

      Note

      Make sure that the bolts are fully tightened.

  69. INSTALL INVERTER 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. A003XT9E01
      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 }

  70. 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:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Install the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    3. A003XTD

      Connect the engine wire to the engine room main wire.

    4. A003XSM

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

  71. INSTALL NO. 1 INVERTER BRACKET


    1. A003YRXE01

      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 }

  72. INSTALL AIR CLEANER HOSE ASSEMBLY (for 2ZR-FXE)


    1. Install the air cleaner hose assembly and lock the hose clamp.

    2. Connect the ventilation hose.

  73. INSTALL AIR CLEANER HOSE ASSEMBLY (for 5ZR-FXE)


    1. Install the air cleaner hose assembly and lock the hose clamp.

    2. Connect the ventilation hose.

  74. INSTALL AIR CLEANER CASE (for 2ZR-FXE)


    1. Install the air cleaner case with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the wire harness clamp to the air cleaner case.

    3. Connect the No. 4 water by-pass hose to the air cleaner case with the clamp.

    4. Install the air cleaner filter element sub-assembly.

  75. INSTALL AIR CLEANER CASE (for 5ZR-FXE)


    1. Install the air cleaner case with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the wire harness clamp to the air cleaner case.

    3. Connect the No. 4 water by-pass hose to the air cleaner case with the clamp.

    4. Install the air cleaner filter element sub-assembly.

  76. INSTALL INLET AIR CLEANER (for 2ZR-FXE)


    1. Install the inlet air cleaner with the 2 bolts and 2 clips.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the wire harness clamp to the inlet air cleaner.

    3. Connect the No. 4 water by-pass hose to the inlet air cleaner with the clamp.

  77. INSTALL INLET AIR CLEANER (for 5ZR-FXE)


    1. Install the inlet air cleaner with the 2 bolts and 2 clips.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the wire harness clamp to the inlet air cleaner.

    3. Connect the No. 4 water by-pass hose to the inlet air cleaner with the clamp.

  78. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FXE)


    1. Install the air cleaner cap sub-assembly with the 2 clamps and hose band.

    2. Connect the No. 4 water by-pass hose to the air cleaner cap sub-assembly with the clamp.

    3. Connect the air flow meter connector.

  79. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 5ZR-FXE)


    1. Install the air cleaner cap sub-assembly with the 2 clamps.

    2. Tighten the hose clamp.

    3. Connect the mass air flow meter connector.

    4. Connect the wire harness clamp.

  80. 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.

      A003X0M

    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.

  81. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  82. 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.

  83. INSTALL DECK FLOOR BOX RH


    1. Engage the 6 guides.

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

  84. INSTALL REAR NO. 3 FLOOR BOARD


    1. Install the rear No. 3 floor board.

  85. INSTALL REAR DECK FLOOR BOX


    1. Install the rear deck floor box.

  86. INSTALL REAR NO. 2 FLOOR BOARD


    1. Install the rear No. 2 floor board.

  87. ADD HYBRID TRANSAXLE FLUID


    1. A003VF8E01
      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.

  88. 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 stored.

      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

    1. A003W8W

      Slowly pour coolant into the reserve tank until it reaches the full 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. Enter the following menus: Powertrain / Hybrid Control / Active Test / Activate the Water Pump.

      4. Keep the coolant at the full 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.

    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 full 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 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.

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

    5. A003W8W

      Add coolant to the full line of the reserve tank.

  89. ADD COOLANT (for Engine)

    for 2ZR-FXE Click here

    for 5ZR-FXE Click here

  90. INSPECT HYBRID TRANSAXLE FLUID


    1. A003VDTE01
      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 }

  91. 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. A003V28

      Install a radiator cap tester.

    3. Pump the radiator cap tester to 122 kPa (1.2 kgf/ cm2, 18 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.

  92. INSPECT FOR COOLANT LEAK (for Engine)

    for 2ZR-FXE Click here

    for 5ZR-FXE Click here

  93. INSPECT FOR EXHAUST GAS LEAK

  94. INSTALL NO. 1 ENGINE UNDER COVER

  95. INSTALL FRONT LOWER BUMPER ABSORBER

  96. INSTALL REAR ENGINE UNDER COVER LH

  97. INSTALL REAR ENGINE UNDER COVER RH

  98. INSTALL FRONT WHEEL (for 2ZR-FXE)

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  99. INSTALL FRONT WHEEL (for 5ZR-FXE)

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  100. INSTALL HOOD SUB-ASSEMBLY


    1. Install the hood sub-assembly with the 4 bolts.

      Torque:
      13 N*m  { 132 kgf*cm, 10 ft.*lbf }

    2. Connect the clamp and washer hose.

  101. INSPECT HOOD SUB-ASSEMBLY


    1. Check that the clearance measurements of areas *a through *e are within each standard range.

      A003X1EE01
      Standard Clearance
      Area Measurement Area Measurement
      *a 3.3 to 7.3 mm (0.130 to 0.287 in.) *b -1.5 to 1.5 mm (-0.0591 to 0.0591 in.)
      *c 5.65 to 9.65 mm (0.222 to 0.380 in.) *d 2.5 to 5.5 mm (0.0984 to 0.217 in.)
      *e -0.6 to 2.4 mm (-0.0236 to 0.0945 in.) - -

  102. ADJUST HOOD SUB-ASSEMBLY


    1. Horizontally and vertically adjust the hood.


      1. A003VC1

        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 rubbers.


      1. A003XN6

        Adjust the 4 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 4 cushion rubbers.

    3. w/o Dynamic Radar Cruise Control System:


      1. Remove radiator support opening cover Click here.

    4. w/ Dynamic Radar Cruise Control System:


      1. Remove millimeter wave radar sensor assembly Click here.

    5. Adjust the hood lock.


      1. A003W68E01
        Text in Illustration
        *1 Protective Tape

        Using a screwdriver, remove the hood lock nut cap.

        Tech Tips

        Tape the screwdriver tip before use.

      2. A003VSIE01
        Text in Illustration
        *1 Hood Lock Bolt

        Loosen the 2 bolts and hood lock bolt.

      3. Adjust the hood lock and tighten the 2 bolts and hood lock bolt.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

      4. Check that the striker can engage with the hood lock smoothly.

    6. A003W5C

      Install a new hood lock nut cap.

    7. w/o Dynamic Radar Cruise Control System:


      1. Install radiator support opening cover Click here.

    8. w/ Dynamic Radar Cruise Control System:


      1. Install millimeter wave radar sensor assembly Click here.

  103. INSTALL SUSPENSION TOWER DAMPER


    1. A003VPIE02
      Text in Illustration
      *1 Label
      *a LH Side
      *b RH Side

      Install the suspension tower damper with the 2 nuts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Tech Tips

      Make sure to install the suspension tower damper with the label facing upright.

  104. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    1. Install the outer cowl top panel sub-assembly with the 9 bolts.

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

    2. w/ Wiper Deicer:

      Engage the 3 clamps to install the wire harness.

    3. Engage the clamp to install the wire harness.

  105. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    1. Install the outer cowl top panel sub-assembly with the 9 bolts.

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

    2. w/ Wiper Deicer:

      Engage the 3 clamps to install the wire harness.

    3. Engage the clamp to install the wire harness.

  106. INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for LHD)


    1. Install the cowl body mounting reinforcement LH with the 2 bolts.

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

  107. INSTALL COWL BODY MOUNTING REINFORCEMENT RH (for RHD)


    1. Install the cowl body mounting reinforcement RH with the 2 bolts.

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

  108. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    1. Engage the claw and guide to install the No. 2 heater air duct splash shield seal.

  109. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. Engage the claw and guide to install the No. 2 heater air duct splash shield seal.

  110. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    1. Engage the 2 claws to install the No. 1 heater air duct splash shield seal.

  111. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. Engage the 2 claws to install the No. 1 heater air duct splash shield seal.

  112. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  113. INSTALL NO. 2 CYLINDER HEAD COVER (for 2ZR-FXE)


    1. A003WMM

      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.

  114. INSTALL NO. 2 CYLINDER HEAD COVER (for 5ZR-FXE)


    1. A003WMM

      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.

  115. 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).

  116. INSTALL INVERTER COVER ASSEMBLY LH (w/ Cover)


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

    2. Install the 2 clips.

  117. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  118. CHECK ABS SPEED SENSOR SIGNAL

    Click here