ENGINE ASSEMBLY INSTALLATION

INSTALL ENGINE HANGER

1. 

   Text in Illustration

   *1	No. 1 Engine Hanger
   *2	No. 2 Engine Hanger
   *a	Claw
   *b	Groove

   Install the No. 1 engine hanger with the bolt.

   Torque:

   43 N*m  { 438 kgf*cm, 32 ft.*lbf }

   HINT

   No. 1 engine hanger	12281-36060
   No. 2 engine hanger	12282-36061
   Bolt (No. 1 engine hanger)	91552-81040
   Bolt (No. 2 engine hanger)	90119-12285

2. Align the claw of the No. 2 engine hanger with the groove of the cylinder head sub-assembly and install the No. 2 engine hanger with the bolt.

   Torque:

   43 N*m  { 438 kgf*cm, 32 ft.*lbf }

   Note

   When installing the No. 2 engine hanger, make sure the No. 2 engine hanger is securely installed to the cylinder head sub-assembly with the bolt.

3. Using an engine sling device and engine lifter, secure the engine assembly.

   Note

   
   

   • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hanger from deforming or becoming damaged.

   • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed or removed from an engine stand.

INSTALL INTAKE MANIFOLD

INSTALL NO. 2 EGR PIPE (w/ EGR System)

1. 

   Text in Illustration

   *1	No. 2 EGR Pipe Gasket
   *a	Claws
   	Nut
   	Bolt

   Install a new No. 2 EGR pipe gasket to the No. 2 EGR pipe as shown in the illustration.

   Note

   Make sure that the gasket is installed in the correct direction.

2. Install a new EGR inlet gasket to the intake manifold.

3. Temporarily install the No. 2 EGR pipe to the EGR valve assembly and intake manifold with the 2 bolts and 2 nuts.

   Tech Tips

   Tighten the bolts and nuts until they are seated on the No. 2 EGR pipe.

4. Tighten the 2 nuts while pressing the No. 2 EGR pipe against the EGR valve assembly side.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

5. Tighten the 2 bolts.

   Torque:

   25 N*m  { 255 kgf*cm, 18 ft.*lbf }

INSTALL PURGE VSV

1. Install the purge VSV to the wire harness clamp bracket with the bolt.

   Torque:

   18 N*m  { 184 kgf*cm, 13 ft.*lbf }

2. Connect the purge VSV connector.

3. Connect the No. 2 fuel vapor feed hose to the purge VSV.

4. Connect the No. 2 fuel vapor feed hose to the purge VSV and slide the clip to secure the hose.

INSTALL INJECTOR DRIVER

1. Install the injector driver to the intake manifold with the 2 bolts and 2 nuts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

2. 

   Text in Illustration

   *a	Lock Lever
   *b	Connector (with Lock)

   Connect the 2 injector driver connectors.

3. Connect the connector (with lock) to the injector driver and move the lock lever as shown in the illustration to engage the lock.

   Note

   Securely connect the connector (with lock) to the injector driver and engage the lock lever.

INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

1. 

   Text in Illustration

   *a	Protrusion

   Install a new throttle body gasket onto the intake manifold with the protrusion of the throttle body gasket oriented as shown in the illustration.

2. Install the throttle body with motor assembly to the intake manifold with the 4 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

   Tech Tips

   Perform "Inspection After Repairs" after replacing the throttle body with motor assembly.

   
   

   • w/ EGR System: Click here

   • w/o EGR System: Click here

3. Connect the No. 2 water by-pass hose and No. 3 water by-pass hose to the throttle body with motor assembly, and slide the 2 clamps to secure the hoses.

4. Connect the throttle body with motor assembly connector.

INSTALL FAN AND GENERATOR V BELT

INSTALL FLYWHEEL SUB-ASSEMBLY

INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY

INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY

1. 

   Text in Illustration

   *1

   Knock Pin

   Make sure that the 2 knock pins are installed to the engine assembly.

2. Using a transmission jack, align the engine assembly and hybrid vehicle transmission assembly, fit the knock pins into the knock pin holes, and tighten the 9 bolts.

   Torque:

   Bolt (A)

   71 N*m  { 724 kgf*cm, 52 in.*lbf }

   Bolt (B)

   37 N*m  { 377 kgf*cm, 27 in.*lbf }

   Note

   
   

   • Make sure to align the hybrid vehicle transmission assembly so that the input shaft of the hybrid vehicle transmission assembly will be inserted straight into the inner splines of the transmission input damper assembly.

   • Do not use excess force when installing the hybrid vehicle transmission assembly.

   • When mounting the hybrid vehicle transmission assembly to the engine assembly, make sure to securely fit the knock pins into the knock pin holes.

   • When tightening the bolts, be sure that the contact surfaces of the engine assembly and the hybrid vehicle transmission assembly are in close contact with one another.

   • Do not apply grease either to the inner splines or to the input shaft.

   Tech Tips

   
   

   Bolt Length

   • Bolt (A): 50 mm (1.97 in.)

   • Bolt (B): 43 mm (1.69 in.)

INSTALL OIL COOLER WITHOUT HOSE TUBE SUB-ASSEMBLY

1. 

   Text in Illustration

   *a	2 to 7 mm (0.0787 to 0.275 in.)
   *b	Marking
   *c	Center of the marking
   *d	Within 45° of the center of the clip

   Install the oil cooler without hose tube sub-assembly to the engine assembly with the 2 bolts.

   Torque:

   22 N*m  { 224 kgf*cm, 16 ft.*lbf }

   Note

   Tighten the 2 bolts in the order of (A) and (B).

2. Connect the oil cooler without hose tube sub-assembly to the 2 elbows, and slide the 2 clips to secure it.

INSTALL WIRE HARNESS

1. Connect the 2 clamps and wire harness to the hybrid vehicle transmission assembly.

2. Connect the shift lever position sensor connector.

3. Install the wire harness to the hybrid vehicle transmission assembly with the 3 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

4. Connect the 2 clamps and wire harness to the hybrid vehicle transmission assembly.

5. Connect the motor resolver sensor connector.

6. Connect the generator resolver sensor connector.

INSTALL MOTOR HEAT INSULATOR

INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

1. Install the No. 1 exhaust manifold heat insulator to exhaust manifold converter sub-assembly with the 4 bolts.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

   Note

   
   

   • The No. 1 exhaust manifold heat insulator rattles even with the bolts tightened to the specified torque.

   • Overtightening the bolts may damage the No. 1 exhaust manifold heat insulator.

INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH

CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

1. 

   Text in Illustration

   *a	Matchmark
   *b	Vehicle Interior

   Align the matchmark on the steering sliding with shaft yoke with the matchmark on the power steering link and install the bolt.

   Torque:

   35 N*m  { 360 kgf*cm, 26 ft.*lbf }

2. Tighten the bolt closest to the vehicle interior.

   Torque:

   35 N*m  { 360 kgf*cm, 26 ft.*lbf }

INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING ASSEMBLY

1. 

   Text in Illustration

   *a

   90°

   Adjust the distance (A) between the surface of the center support bearing and the surface of the cushion to 11.5 to 13.5 mm (0.453 to 0.531 in.) as shown in illustration.

   Distance (A)
   11.5 to 13.5 mm (0.453 to 0.531 in.)

2. Check that the center line of the bracket is at right angles to the shaft axial direction.

3. for 2GR-FXE:

   Tighten the 2 center support bearing dampers.

   Torque:

   49 N*m  { 501 kgf*cm, 36 ft.*lbf }

4. for 2AR-FSE:

   Tighten the 2 bolts.

   Torque:

   49 N*m  { 501 kgf*cm, 36 ft.*lbf }

5. 

   Text in Illustration

   *a	Turn
   *b	Hold

   Using SST, tighten the adjusting nut.

   SST

   09922-10010

   Torque:

   without SST

   69 N*m  { 704 kgf*cm, 51 ft.*lbf }

   with SST

   47 N*m  { 479 kgf*cm, 35 ft.*lbf }

   Tech Tips

   Use a torque wrench with a fulcrum length of 34.5 cm (13.6 in.).

INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE

INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR

1. Install the front No. 1 floor heat insulator with the 4 nuts.

   Torque:

   5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

INSTALL NO. 1 FUEL TANK PROTECTOR

INSTALL FRONT EXHAUST PIPE ASSEMBLY

INSTALL FRONT CENTER FLOOR BRACE

1. Install the front center floor brace and tighten the 2 clips.

2. Install the 6 bolts and 2 nuts.

   Torque:

   19 N*m  { 194 kgf*cm, 14 ft.*lbf }

INSTALL NO. 2 REAR FLOOR BOARD SUB-ASSEMBLY

INSTALL NO. 1 REAR FLOOR BOARD SUB-ASSEMBLY

INSTALL HV WATER PUMP BRACKET SUB-ASSEMBLY

1. 

   Text in Illustration

   *a

   Claw

   Install the HV water pump bracket sub-assembly with 2 bolts.

   Torque:

   13 N*m  { 127 kgf*cm, 9 ft.*lbf }

   Note

   Attach the claw of the HV water pump bracket sub-assembly to the hole in the body as shown in the illustration.

2. 

   Text in Illustration

   *a	Upper
   *b	Front
   *c	RH Side
   *d	30°

   Connect the hybrid water pump inlet hose and No. 1 hybrid water pump outlet hose to the inverter water pump with motor assembly, and slide the 2 clamps to secure the hose.

   Note

   
   

   • Make sure that the clamps are positioned as shown in the illustration.

   • Do not remove the pieces of cloth or plastic bags from the pipe and disconnected hose until installation.

3. Attach the 2 clamps and connect the inverter water pump connector.

4. Attach the inverter cooling hose clamp to the HV water pump bracket sub-assembly.

INSTALL ECM

CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

1. Remove the attached vinyl tape from the No. 1 cooler refrigerant discharge hose.

2. Apply sufficient compressor oil (ND-OIL 11) to a new O-ring and the fitting surface of the compressor with motor assembly.

   Compressor oil
   ND-OIL 11 or equivalent

3. Install the O-ring to the No. 1 cooler refrigerant discharge hose.

4. Connect the No. 1 cooler refrigerant discharge hose to the compressor with motor assembly with the bolt.

   Torque:

   9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

CONNECT SUCTION HOSE

1. Remove the attached vinyl tape from the suction hose.

2. Apply sufficient compressor oil (ND-OIL 11) to a new O-ring and the fitting surface of the compressor with motor assembly.

   Compressor oil
   ND-OIL 11 or equivalent

3. Install the O-ring to the suction hose.

4. Connect the suction hose to the compressor with motor assembly with the bolt.

   Torque:

   9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

INSTALL HEATER WATER PUMP ASSEMBLY

1. 

   Text in Illustration

   *1	Paint Mark (Orange)
   *2	Paint Mark (Yellow)
   *a	Clip Installation Angle +/- 15 °

   Connect the heater water inlet hose A and heater water inlet hose B to the heater water pump assembly and slide the 2 clips to secure the 2 hoses as shown in the illustration.

   Note

   Do not apply excessive force to the heater water inlet hose.

2. Install the heater water pump assembly with the 2 bolts.

   Torque:

   9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

3. Attach the harness clamp and connect the connector.

CONNECT HEATER WATER HOSE INLET A

1. 

   Text in Illustration

   *a	Brown Marking 5 mm
   *b	Brown Marking 2 mm
   *c	45° +/- 15°
   *d	0° +/- 15°

   Connect the heater water inlet hose A and attach the clip.

CONNECT HEATER WATER HOSE OUTLET A

1. Connect the heater water outlet hose A and attach the clip.

CONNECT NO. 2 RADIATOR HOSE SUB-ASSEMBLY

1. Connect the No. 2 radiator hose sub-assembly to the water inlet with thermostat sub-assembly and slide the clip to secure the hose.

INSTALL RADIATOR HOSE SUB-ASSEMBLY

1. Install the radiator hose sub-assembly to the water outlet sub-assembly and radiator assembly, and slide the 2 clamps to secure the hoses.

CONNECT MOTOR CABLE

1. Temporarily install the motor cable with the 5 bolts.

2. 

   Text in Illustration

   *A	for LHD
   *B	for RHD

   Using an insulated tool, tighten the 3 bolts labeled A in the illustration.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

   Note

   
   

   • The connector should be connected securely.

   • The bolts should be tightened securely.

   • Tighten the bolts in the order shown in the illustration.

3. Using an insulated tool, tighten the 2 bolts labeled B in the illustration.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

   Note

   
   

   • The connector should be connected securely.

   • The bolts should be tightened securely.

CONNECT GENERATOR CABLE

1. Temporarily install the generator cable with the 5 bolts.

2. 

   Text in Illustration

   *A	for LHD
   *B	for RHD

   Using an insulated tool, tighten the 3 bolts labeled A in the illustration.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

   Note

   
   

   • The connector should be connected securely.

   • The bolts should be tightened securely.

   • Tighten the bolts in the order shown in the illustration.

3. Using an insulated tool, tighten the 2 bolts labeled B in the illustration.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

   Note

   
   

   • The connector should be connected securely.

   • The bolts should be tightened securely.

INSTALL INVERTER TERMINAL COVER

1. for Type A:

   
   

   1. Using an insulated tool, install the inverter terminal cover with the 2 bolts.

      Torque:

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

      Note

      
      

      • Do not touch the inverter terminal cover waterproofing rubber.

      • Visually confirm that the inverter terminal cover waterproofing rubber is securely installed before installing the inverter terminal cover.

      • Press down on the inverter terminal cover with both hands to securely connect the interlock.

2. for Type B:

   
   

   1. Using an insulated tool, install the inverter terminal cover with the 3 bolts.

      Torque:

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

      Note

      
      

      • Do not touch the inverter terminal cover waterproofing rubber.

      • Visually confirm that the inverter terminal cover waterproofing rubber is securely installed before installing the inverter terminal cover.

      • Press down on the inverter terminal cover with both hands to securely connect the interlock.

INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY

1. Install the inverter motor cable bracket assembly with the 2 bolts.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

2. Attach the 2 clamps to the inverter motor cable bracket assembly.

INSTALL AIR CLEANER HOSE ASSEMBLY

1. 

   Text in Illustration

   *a	Cutout
   *b	Protrusion

   Align the cutout of the air cleaner hose assembly with the protrusion of the throttle body with motor assembly, and install the air cleaner hose assembly.

2. Tighten the hose clamp.

   Torque:

   4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

   Note

   Fit the protrusion on the air cleaner hose assembly into the hole of the hose clamp.

3. Connect the ventilation hose to the throttle body with motor assembly, and slide the clamp to secure the hose.

INSTALL AIR CLEANER CAP WITH NO. 2 AIR CLEANER HOSE

1. 

   Text in Illustration

   *a	Groove
   *b	Matchmark

   Connect the air cleaner cap with No. 2 air cleaner hose to the air cleaner hose assembly.

   Tech Tips

   Make sure the direction of the installation is as shown in the illustration.

2. Attach the 4 clamps to install the air cleaner cap with No. 2 air cleaner hose.

3. Tighten the hose clamp.

   Torque:

   4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

4. Connect the wire harness clamp to the air cleaner cap with No. 2 air cleaner hose.

5. Connect the mass air flow meter sub-assembly connector.

INSTALL SERVICE PLUG GRIP

CAUTION:

Wear insulated 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.

Text in Illustration

*1

Lever

-

-

1. Install the service plug grip in the order shown in the illustration.

   
   

   1. Insert the service plug grip and rotate the lever.

   2. Slide the lever until a click sound is heard to lock the lever.

INSTALL LOWER HYBRID VEHICLE BATTERY COVER PANEL

1. 

   Text in Illustration

   *1

   Arrow

   Install the lower hybrid vehicle battery cover panel with the 4 nuts.

   Tech Tips

   Be sure to install the lower hybrid vehicle battery cover panel with its arrow facing upwards.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

INSTALL NO. 1 SEAT ARMREST CAP

1. Attach the 4 guides and 4 claws to install the No. 1 seat armrest cap.

CONNECT CABLE TO AUXILIARY BATTERY NEGATIVE TERMINAL

1. Connect the cable to the auxiliary battery negative (-) terminal.

   Torque:

   5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

INSTALL LUGGAGE COMPARTMENT TRIM COVER LH

1. Install the luggage compartment trim cover LH.

INSTALL LUGGAGE COMPARTMENT FLOOR MAT

1. Install the luggage compartment floor mat.

ADD ENGINE OIL

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

   Standard Oil Grade

   Oil Grade	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	Specified Condition
   Drain and refill without oil filter change	4.1 liters (4.3 US qts, 3.6 Imp. qts)
   Drain and refill with oil filter change	4.5 liters (4.8 US qts, 4.0 Imp. qts)
   Dry fill	5.9 liters (6.2 US qts, 5.2 Imp. qts)

ADD COOLANT (for Inverter)

1. Tighten the drain cock plug.

2. Slowly pour coolant into the reservoir tank until it reaches the FULL line.

   Standard Capacity
   Item Specified Condition for LHD 2.1 liters (2.2 US qts, 1.8 Imp. qts) for RHD 2.3 liters (2.4 US qts, 2.0 Imp. qts)

   Note

   To prevent foreign matter such as dust or dirt from entering the cooling system, make sure to confirm that the container used to add coolant is clean and free of foreign matter such as dust or dirt.

3. When using the GTS:

   
   

   1. Connect the GTS 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 reservoir 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 reservoir tank improves.

      Tech Tips

      
      

      • If free spinning of the inverter water pump is detected for approximately 5 seconds, failsafe control will be activated to suspend the operation of the pump for approximately 15 seconds and resume operation for approximately 4 seconds repeatedly. Operation of the inverter water pump will return to normal if coolant is added.

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

4. When not using the GTS:

   
   

   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 reservoir tank improves.

      Tech Tips

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

5. After the air is completely bled from the cooling system, tighten the reservoir tank cap.

6. Add coolant to the FULL line of the reservoir tank.

ADD ENGINE COOLANT (for Engine)

1. Tighten the radiator drain cock sub-assembly by hand.

2. Remove the vinyl tube from the radiator drain cock.

3. Install the No. 4 center engine under cover with the 3 screws.

4. 

   Text in Illustration

   *a	[AR] B line

   Add engine coolant to the [AR] B line of the radiator reservoir tank assembly. [*1]

   Standard Capacity
   Item Specified Condition Engine Coolant 8.4 liters (8.9 US qts, 7.4 Imp. qts)

   Note

   
   

   • Do not reverse the position of the reservoir tank cap and water filler cap sub-assembly when installing them. Doing so may damage the parts.

   • Do not substitute plain water for engine coolant.

   • Apply a light coat of engine coolant to the O-ring of the water filler cap sub-assembly when installing the water filler cap sub-assembly.

   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).

5. Install the reservoir tank cap.

6. Add engine coolant to the radiator pipe filler hole.

   Tech Tips

   
   

   • Install the water filler cap sub-assembly.

   • Squeeze radiator hose sub-assembly and No. 2 radiator hose sub-assembly several times by hand, and then check the level of the engine coolant.

     If the engine coolant level is low, add engine coolant.

7. Put the engine in inspection mode (maintenance mode). [*2] Click here

8. Bleed air from the cooling system. [*3]

   CAUTION:

   
   

   • 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 water inlet with thermostat sub-assembly opens. While the water inlet with thermostat sub-assembly is open, circulate the engine coolant for several minutes.

      CAUTION:

      When squeezing the radiator hose sub-assembly and No. 2 radiator hose sub-assembly :

      
      

      • Wear protective gloves.

      • Be careful as the radiator hose sub-assembly and No. 2 radiator hose sub-assembly are hot.

      • Keep your hands away from the fan and No. 2 fan.

      Note

      
      

      • Make sure that the radiator reservoir tank assembly still has some engine coolant in it.

      • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

      • If there is not enough engine coolant, the engine may overheat or be seriously damaged.

      • If the radiator reservoir tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant cools down, and 3) add engine coolant until the radiator reservoir tank assembly is filled to the full line.

      Tech Tips

      The water inlet with thermostat sub-assembly open timing can be confirmed by squeezing the radiator hose sub-assembly by hand, and sensing vibrations when the engine coolant starts to flow inside the No. 2 radiator hose sub-assembly.

   2. Squeeze the radiator hose sub-assembly and No. 2 radiator hose sub-assembly several times by hand to bleed air.

   3. Stop the engine, and wait until the engine coolant cools down. [*4]

   4. Check that the engine coolant level is between the full and low. [*5]

      Tech Tips

      
      

      • If the engine coolant level is below the low, repeat steps from [*1] to [*5].

      • If the engine coolant level is above the full, drain engine coolant so that the engine coolant level is between the full and low.

ADJUST SHIFT LEVER POSITION

INSPECT SHIFT LEVER POSITION

1. When shifting from P to R with the power switch on (IG) and the brake pedal depressed, make sure that the shift lever moves smoothly and moves correctly into position.

2. Start the engine and make sure that the vehicle moves forward when shifting from N to D and moves rearward when shifting to R. If the operation cannot be done as specified, inspect the shift lever position sensor and check the shift lever assembly installation condition.

INSPECT FOR COOLANT LEAK (for Inverter)

INSPECT FOR COOLANT LEAK (for Engine)

INSPECT FOR OIL LEAK

1. Put the engine in inspection mode (maintenance mode) Click here

2. Start the engine. Make sure that there are no oil leaks from the area that was worked on.

INSPECT FOR FUEL LEAK

1. Check fuel pump with filter assembly operation.

   
   

   1. Connect the GTS to the DLC3.

   2. Turn the power switch on (IG).

      Note

      Do not start the engine.

   3. Turn the GTS on.

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

   5. Check for pressure in the fuel tube sub-assembly from the fuel line. Check that sounds of fuel flowing from the fuel tank assembly can be heard.

      If no sounds can be heard, check the No. 1 integration relay, fuel pump with filter assembly, ECM and wiring connectors.

2. Inspect for fuel leaks.

   
   

   1. Check that there are no fuel leaks from the fuel system after doing any maintenance or repairs.

      If there is a fuel leak, repair or replace parts as necessary.

3. Turn the power switch off.

4. Disconnect the GTS from the DLC3.

INSPECT FOR EXHAUST GAS LEAK

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

WARM UP COMPRESSOR

1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

   Note

   To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing air conditioning system lines (including the compressor).

INSPECT FOR REFRIGERANT LEAK

1. After recharging the air conditioning system with refrigerant, check for refrigerant leaks using a halogen leak detector.

2. Carry out the test under the following conditions:

   
   

   • Power switch off.

   • Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as gasoline vapor and exhaust gas).

   • Repeat the inspection 2 or 3 times.

   • Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system (pressure when the compressor is off: approx. 392 to 588 kPa (3.9 to 5.9 kgf/cm2, 57 to 85 psi)).

3. 

   Text in Illustration

   *1	Halogen Leak Detector
   *a	Check for Leak

   Using a halogen leak detector, check for refrigerant leaks from the air conditioning system.

4. If a refrigerant leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the halogen leak detector sensor into the unit and check for a leak.

5. Disconnect the pressure sensor connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure sensor and check for a leak.

   Tech Tips

   When checking for leaks, the presence of oily dirt at a joint can indicate a leak.

INSPECT IGNITION TIMING

1. Put the engine in inspection mode (maintenance mode) Click here.

2. Warm up and stop the engine.

   Tech Tips

   A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine speed should be stabilized.

3. When using the GTS:

   Check the ignition timing.

   
   

   1. Connect the GTS to the DLC3.

   2. Put the engine in inspection mode (maintenance mode) Click here.

   3. Enter the following menus: Powertrain / Engine and ECT / Data List / IGN Advance.

      Standard ignition timing
      5 to 20° BTDC @ idle

      Note

      
      

      • Check the ignition timing with the cooling fan off.

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

      • When checking the ignition timing, the shift lever should be in P.

   4. Check that the ignition timing advances immediately when the engine speed is increased.

   5. Enter the following menus: Powertrain / Engine and ECT / Active Test / Connect the TC and TE1 / ON.

   6. Monitor IGN Advance of the Data List.

      Standard ignition timing
      8 to 12° BTDC @ idle

      Note

      
      

      • Check the ignition timing with the cooling fan off.

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

      • When checking the ignition timing, the shift lever should be in P.

   7. Enter the following menus: Connect the TC and TE1 / OFF.

   8. Check that the ignition timing advances immediately when the engine speed is increased.

4. When not using the GTS:

   
   
   1. 

      Text in Illustration

      *a	Front view of DLC3

      Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.

      SST

      09843-18040

      Note

      
      

      • Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

      • Check the ignition timing with the cooling fan off.

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

      • When checking the ignition timing, the shift lever should be in P.

   2. Remove the No. 1 engine cover sub-assembly Click here.

   3. Connect the timing light probe to the ignition coil wire for the No. 1 cylinder.

      Note

      Use a timing light that detects primary signals.

   4. Put the engine in inspection mode (maintenance mode) Click here.

   5. Inspect the ignition timing at idle.

      Standard ignition timing
      8 to 12° BTDC @ idle

      Note

      
      

      • Check the ignition timing with the cooling fans off.

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

      • When checking the ignition timing, the shift lever should be in P.

      If the ignition timing is not as specified, check the valve timing.

   6. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.

   7. Inspect the ignition timing at idle.

      Standard ignition timing
      5 to 20° BTDC @ idle

      Note

      
      

      • Check the ignition timing with the cooling fans off.

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

      • When checking the ignition timing, the shift lever should be in P.

   8. Check that the ignition timing advances immediately when the engine idle speed is increased.

   9. Remove the timing light probe from the engine.

   10. Install the No. 1 engine cover sub-assembly Click here.

INSPECT ENGINE IDLE SPEED

1. Put the engine in inspection mode (maintenance mode) Click here.

2. Warm up and stop the engine.

   Tech Tips

   A warmed up engine should have an engine coolant temperature of over 80°C (176°F), an engine oil temperature of 60°C (140°F), and the engine idle speed should be stabilized.

3. When using the GTS:

   
   

   1. Connect the GTS to the DLC3.

   2. Put the engine in inspection mode (maintenance mode) Click here.

   3. Start the engine and run it at idle.

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

   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 engine idle speed, the shift lever should be in P.

4. When not using the GTS:

   
   
   1. 

      Text in Illustration

      *a	Front view of DLC3

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

      SST

      09843-18030

      Note

      Be sure to connect the tachometer to the correct terminal. Connecting the wrong terminals can cause damage to electrical components.

   2. Put the engine in inspection mode (maintenance 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 engine idle speed, the shift lever should be in P.

   4. Turn the power switch off.

   5. Disconnect the tachometer probe from terminal 9 (TAC) of the DLC3.

INSPECT CO/HC

1. Put the engine in inspection mode (maintenance mode) Click here.

2. Warm up the engine.

3. Keep the engine speed 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. Immediately check the CO/HC concentration while idling and when the engine is running at 2500 rpm.

   Tech Tips

   
   

   • When performing the 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, perform troubleshooting in the following order.

   
   

   1. Check the DTCs.

      
      

      • w/ EGR System: Click here

      • w/o EGR System: Click here

   2. See the following table 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 spark plugs Incorrect valve clearance Leaks in intake or exhaust valves Leaks in cylinders Faulty EGR (w/ EGR System)
      Low	High	Rough idle (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle with motor body assembly Lean mixture causing misfire Faulty EGR (w/ EGR System)
      High	High	Rough idle (Black smoke from exhaust)	Restricted air cleaner filter element sub-assembly Plugged PCV valve Faulty EFI systems: Fuel pressure regulator assembly Engine coolant temperature sensor Mass air flow meter ECM Fuel injector assemblies Throttle body assembly Faulty EGR (w/ EGR System)

INSPECT ENGINE COOLANT LEVEL IN RESERVOIR (for Engine)

1. Check that the engine coolant level is between the "LOW" and "FULL" when the engine is cold.

   If the engine coolant level is low, check for leaks and add TOYOTA Super Long Life Coolant (SLLC) or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite and non-borate coolant with long-life hybrid organic acid technology to the "FULL" .

   Note

   Do not substitute plain water for engine coolant.

INSPECT COOLANT LEVEL IN RESERVOIR TANK (for Inverter)

1. The coolant should be between the LOW and FULL lines when the coolant for the inverter is cold.

   Tech Tips

   If the coolant level is low, check for leaks and add TOYOTA Super Long Life Coolant (SLLC) or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate coolant with long-life hybrid organic acid technology up to the FULL line.

INSPECT ENGINE OIL LEVEL

1. Put the engine in inspection mode (maintenance mode) Click here.

2. Warm up the engine, stop it and wait 5 minutes. The engine oil level should be between the low level mark and full level mark on the engine oil level dipstick.

   If the engine oil level is low, check for leaks and add engine oil to the full level mark.

   Note

   Do not add engine oil to above the full level mark.

   Tech Tips

   A certain amount of engine oil will be consumed while driving. In the following situations, oil consumption may increase, and engine oil may need to be refilled in between oil maintenance intervals.

   
   

   • When the engine is new, for example directly after purchasing the vehicle or after replacing the engine.

   • If low quality oil or oil of an inappropriate viscosity is used.

   • When driving at high engine speeds or with a heavy load (when towing, etc.), or when accelerating or decelerating frequently while driving.

   • When leaving the vehicle idling for a long time, or when driving frequently in heavy traffic.

   When judging the amount of oil consumption, keep in mind that the oil may have become diluted, making it difficult to judge the true level accurately.