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Engine Assembly: Installation

  1. INSTALL KNOCK CONTROL SENSOR  (See INSTALLATION )
  2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Apply adhesive to 2 or 3 threads of the oil pressure switch.

      Adhesive: 

      Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent. 

      Fig 1: Applying Adhesive To Threads Of Oil Pressure Switch
      G04974196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a deep socket wrench 24 mm, install the oil pressure switch.

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

      Fig 2: Installing Oil Pressure Switch
      G05200506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL THERMOSTAT  (See INSTALLATION )
  4. INSTALL WATER INLET  (See INSTALLATION )
  5. INSTALL WATER INLET PIPE  (See INSTALLATION )
  6. INSTALL INTAKE AIR CONNECTOR BRACKET NO.2 
    1. Install the intake air connector bracket No.2 with the 2 bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

      Fig 3: Locating Intake Air Connector Bracket Bolts
      G05200507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 
    1. Temporarily install the mounting bracket with the 4 bolts.
    2. Install the mounting bracket by tightening the 4 bolts in the order shown in the illustration.
      Fig 4: Identifying Tightening Sequence Of Mounting Bracket Bolts
      G05200508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL ENGINE MOUNTING STAY BRACKET 
    1. Install the 3 bolts, nut and engine mounting stay bracket.

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

    Fig 5: Locating Engine Mounting Stay Bracket Bolts And Nut
    G05200501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL ENGINE MOUNTING BRACKET RH 
    1. Install the 3 bolts and engine mounting bracket RH.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

    Fig 6: Locating Engine Mounting Bracket Bolts (RH)
    G05200500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL ENGINE MOUNTING BRACKET REAR 
    1. Install the 3 bolts and engine mounting bracket rear.

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

      Fig 7: Locating Engine Mounting Bracket Bolts (Rear)
      G05200499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL MANIFOLD STAY NO.2 
    1. Install the 2 bolts and manifold stay No.2.

      Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf) 

  12. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2 (See  INSTALLATION  ) 
  13. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See  INSTALLATION  ) 
  14. INSTALL MANIFOLD CONVERTER INSULATOR NO.3 (See  INSTALLATION  ) 
  15. INSTALL IGNITION COIL ASSEMBLY 

    Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf) 

  16. INSTALL WATER OUTLET (See  INSTALLATION  ) 
  17. INSTALL INTAKE MANIFOLD (See  INSTALLATION  ) 
  18. INSTALL INTAKE AIR SURGE TANK  (See INSTALLATION )
  19. INSTALL EMISSION CONTROL VALVE SET  (See INSTALLATION )
  20. INSTALL ENGINE HANGER NO.2 
    1. Install the No.2 engine hanger in the correct direction shown in the illustration.

      Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf) 

      Fig 8: Identifying Engine Hanger
      G05200493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE ENGINE STAND 
  22. INSTALL FLYWHEEL SUB-ASSEMBLY (See  INSTALLATION  ) 
  23. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY (See  INSTALLATION  ) 
  24. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY  (See INSTALLATION )
  25. INSTALL ENGINE MOUNTING BRACKET FRONT  (See INSTALLATION )
  26. INSTALL FLYWHEEL HOUSING UNDER COVER  (See INSTALLATION )
  27. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH  (See INSTALLATION )
  28. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH  (See INSTALLATION )
  29. INSTALL FRONT FRAME ASSEMBLY 
    1. Install the engine mounting insulators RH and LH with the 2 nuts.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

      Fig 9: Locating Engine Mounting Insulators Nuts
      G05129362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine mounting insulator FR with the nut.

      Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

      Fig 10: Locating Engine Mounting Insulator FR Nut
      G05200496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the engine mounting insulator RR with the 2 bolts.

      Torque: 75 N*m (765 kgf*cm, 55 ft.*lbf) 

    Fig 11: Locating Engine Mounting Insulator RR Bolts
    G05200497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. INSTALL HV TRANSAXLE MASS DAMPER 
    1. Install the bolt and transaxle mass damper.

      Torque: 14 N*m (138 kgf*cm, 10 ft.*lbf) 

      Fig 12: Locating Transaxle Mass Damper Bolt
      G05276041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (See  INSTALLATION  ) 
  32. INSTALL MANIFOLD STAY (See  INSTALLATION  ) 
  33. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See  INSTALLATION  ) 
  34. INSTALL ENGINE WIRE 
  35. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on the engine lifter.
    2. Install the engine assembly to the vehicle.
    3. Install the frame side rail plates RH and LH with the 6 bolts and 2 nuts.

      Torque: Bolt A 

      85 N*m (867 kgf*cm, 63 ft.*lbf) 

      Bolt B 

      32 N*m (326 kgf*cm, 24 ft.*lbf) 

      Nut C 

      32 N*m (326 kgf*cm, 24 ft.*lbf) 

      Fig 13: Locating Frame Side Rail Plates Bolts And Nuts
      G05200517Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.

      Torque: Bolt A 

      85 N*m (867 kgf*cm, 63 ft.*lbf) 

      Bolt B 

      32 N*m (326 kgf*cm, 24 ft.*lbf) 

      Nut C 

      32 N*m (326 kgf*cm, 24 ft.*lbf) 

      Fig 14: Locating Front Suspension Member Brace Bolts And Nuts (Rear)
      G05200518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY  (See INSTALLATION )
  37. INSTALL FRONT AXLE ASSEMBLY LH 
    1. Install the drive shaft assembly LH to the front axle assembly LH.
      NOTE:
      • Be careful not to damage the outboard joint boot.
      • Be careful not to damage the speed sensor rotor.
  38. INSTALL FRONT AXLE ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  39. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH  (See INSTALLATION )
  40. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  41. CONNECT TIE ROD END SUB-ASSEMBLY LH  (See INSTALLATION )
  42. CONNECT TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  43. INSTALL SPEED SENSOR FRONT LH  (See INSTALLATION )
  44. INSTALL SPEED SENSOR FRONT RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  45. INSTALL FRONT AXLE HUB LH NUT  (See INSTALLATION )
  46. INSTALL FRONT AXLE HUB RH NUT 

    HINT:

    Perform the same procedure as above on the opposite side.

  47. INSTALL FRONT STABILIZER LINK ASSEMBLY LH  (See INSTALLATION )
  48. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  49. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.3 
    1. Using vernier calipers, measure the free length of the compression spring.

      Minimum length: 

      41.5 mm (1.634 in.) 

      HINT:

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

      Fig 15: Measuring Free Length Of Compression Spring
      G05239315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install a new gasket to the exhaust pipe front No. 3 as shown in the illustration.
      Fig 16: Identifying Gasket On Exhaust Pipe
      G05200520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.

      Torque: Bolt 

      48 N*m (490 kgf*cm, 35 ft.*lbf) 

      Nut 

      56 N*m (571 kgf*cm, 41 ft.*lbf) 

      Fig 17: Locating Exhaust Pipe Bolts And Nuts
      G05200490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the heated oxygen sensor connector.
  50. INSTALL EXHAUST PIPE ASSEMBLY FRONT 
    1. Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.

      Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf) 

      Fig 18: Locating Exhaust Pipe Assembly Bolts And Nuts
      G05200489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the heated oxygen sensor connector.
  51. CONNECT WIRE HARNESS 
    1. Connect the power steering link connector and clamp.
    2. Install the ground cable.
  52. CONNECT ENGINE WIRE 
    1. Install the 2 nuts and pull in the engine wire harness.

      Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) 

    2. Connect the engine wire harness to the ECM and the junction block.
    3. Install the body ground and connector.
  53. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY  (See INSTALLATION )
  54. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.2  (See INSTALLATION )
  55. CONNECT WATER HOSE 
  56. INSTALL HEATER WATER PUMP ASSEMBLY 
    1. Install the bolt and heater water pump assembly.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

    Fig 19: Locating Heater Water Pump Assembly Bolt
    G05200488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. CONNECT OIL COOLER INLET TUBE SUB-ASSEMBLY (W/ OIL COOLER) 
    1. Using pliers, grip the claws of the clip and slide the clip to connect the oil cooler inlet tube.
    2. Fig 20: Locating Oil Cooler Inlet Tube Clips
      G05200487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. CONNECT OIL COOLER OUTLET TUBE SUB-ASSEMBLY (W/ OIL COOLER) 

    HINT:

    Connection of the oil cooler outlet tube is the same as for the oil cooler inlet tube.

  59. CONNECT RADIATOR HOSE INLET 
  60. CONNECT RADIATOR HOSE OUTLET 
  61. CONNECT HEATER WATER INLET HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to connect the heater water inlet hose.
    2. Fig 21: Identifying Heater Water Inlet Hose And Outlet Hose
      G05200486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. CONNECT HEATER WATER OUTLET HOSE 

    HINT:

    Connection of the heater water outlet hose is the same as for the heater water inlet hose.

  63. CONNECT FUEL PIPE SUB-ASSEMBLY NO.1 
    1. Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel tube sub-assembly to the fuel delivery pipe.
    2. Fig 22: Pushing In Connector To Fuel Pipe
      G05200526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the EFI fuel pipe clamp.
  64. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Install the control cable to the transaxle with the bolt.

      Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf) 

      Fig 23: Locating Control Cable Bolt
      G05200483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the control shaft lever with the nut.

      Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 

      Fig 24: Locating Control Shaft Lever Nut
      G05200482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the control cable and a new clip to the bracket.
  65. INSTALL INVERTER BRACKET NO.1 
    1. Install the 4 bolts and inverter bracket.

      Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

      Fig 25: Locating Inverter Bracket Bolts
      G05200481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the harness clamp and hose clamp.
  66. INSTALL COMPRESSOR W7 MOTOR ASSEMBLY 
    1. Temporarily install the compressor and magnetic clutch with the 3 bolts.
    2. Install the compressor and magnetic clutch by tightening the 3 bolts in the order shown in the illustration.

      Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

      Fig 26: Identifying Tightening Sequence Of Compressor And Magnetic Clutch Bolts
      G05200530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the 2 connectors.
  67. INSTALL ENGINE MOUNTING STAY NO.2 RH (See  INSTALLATION  ) 
  68. INSTALL ENGINE MOVING CONTROL ROD (See  INSTALLATION  ) 
  69. INSTALL AIR CLEANER BRACKET 
    1. Install the 2 bolts and air cleaner bracket.

      Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf) 

      Fig 27: Locating Air Cleaner Bracket Bolts
      G05200479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL RESERVOIR BRACKET 
    1. Install the 2 bolts, nut and reservoir bracket.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      Fig 28: Locating Reservoir Bracket Nut And Bolts
      G05200478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the clamp.
  71. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY 
    1. Install the 2 bolts and brake master cylinder reservoir to the bracket.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      Fig 29: Locating Brake Master Cylinder Reservoir Bolts
      G05200477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the connector.
  72. INSTALL W/ CONVERTER INVERTER ASSEMBLY  (See INSTALLATION )
  73. INSTALL INVERTER BRACKET NO.4  (See INSTALLATION )
  74. INSTALL ENGINE ROOM RELAY BLOCK ASSEMBLY  (See INSTALLATION )
  75. REMOVE INVERTER COVER  (See INSTALLATION )
  76. INSTALL NO.3 WIRE FRAME  (See INSTALLATION )
  77. INSTALL MG ECU CONNECTOR  (See INSTALLATION )
  78. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR  (See INSTALLATION )
  79. INSTALL ENGINE WIRE NO.4  (See INSTALLATION )
  80. CHECK HIGH VOLTAGE CABLE CONNECTION  (See INSTALLATION )
  81. INSTALL INVERTER COVER  (See INSTALLATION )
  82. INSTALL POWER STEERING ECU BRACKET  (See INSTALLATION )
  83. CONNECT WATER HOSE  (See INSTALLATION )
  84. INSTALL INVERTER RESERVE TANK SUB-ASSEMBLY  (See INSTALLATION )
  85. CONNECT ENGINE ROOM WIRE NO.2  (See INSTALLATION )
  86. CONNECT CIRCUIT BREAKER SENSOR NO.1  (See INSTALLATION )
  87. INSTALL POWER STEERING ECU ASSY  (See INSTALLATION )
  88. INSTALL INVERTER BRACKET NO. 5  (See INSTALLATION )
  89. INSTALL AIR CLEANER CASE W/ RESONATOR  (See INSTALLATION )
  90. INSTALL AIR CLEANER CAP W/ INLET 
    1. Install the air cleaner filter element to the air cleaner case.
    2. Install the 2 bolts, 4 clamps and air cleaner cap w/ inlet.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

      Fig 30: Locating Air Cleaner Cap W/Inlet Bolts And Clamps
      G05276023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  91. INSTALL COOL AIR INTAKE DUCT SEAL 
    1. Install the 4 clips and cool air intake duct seal.
  92. INSTALL BATTERY CARRIER SUB-ASSEMBLY 
    1. Install the 5 bolts and battery carrier.

      Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) 

      Fig 31: Locating Battery Carrier Bolts
      G05276082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  93. INSTALL BATTERY 
    1. Install the battery clamp and battery.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

  94. INSTALL SERVICE PLUG GRIP  (See INSTALLATION )
  95. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER 
    1. Remove the 4 shock absorber nuts.
    2. Install the 4 bolts, 2 nuts and cowl top panel sub-assembly.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

      Fig 32: Locating Shock Absorber Nuts And Cowl Top Panel Bolts
      G05276021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 4 shock absorber nuts (B).

      Torque: 80 N*m (815 kgf*cm, 59 ft.*lbf) 

    4. Install the wire harness clamp and grommet (A).
  96. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See INSTALLATION )
  97. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 
  98. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  99. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  100. INSTALL FRONT WHEELS 

    Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 

  101. ADD AND INSPECT HYBRID TRANSAXLE FLUID (W/ O OIL COOLER)  (See HYBRID TRANSAXLE FLUID )
  102. ADD AND INSPECT HYBRID TRANSAXLE FLUID (W7 OIL COOLER)  (See HYBRID TRANSAXLE FLUID )
  103. ADD ENGINE OIL 
  104. ADD COOLANT (for Inverter)  (See REPLACEMENT )
  105. ADD COOLANT (for Engine)  (See COOLANT (for Engine) )
  106. INSPECT FOR OIL LEAK 
  107. INSPECT FOR COOLANT LEAK (for Inverter) 
  108. INSPECT FOR COOLANT LEAK (for Engine)  (See COOLING SYSTEM )
  109. INSPECT FOR FUEL LEAK  (See ON-VEHICLE INSPECTION )
  110. INSPECT FOR EXHAUST GAS LEAK 
  111. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    (See FRONT WHEEL ALIGNMENT )

  112. INSTALL ENGINE UNDER COVER NO.2 
    1. Install the 2 bolts and engine under cover No.2.
  113. INSTALL FRONT FENDER APRON SEAL LH 
    1. Install the 2 bolts, clip and fender apron seal LH.
    2. Fig 33: Locating Fender Apron Seal Clip And Bolts (LH)
      G05276020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  114. INSTALL FRONT FENDER APRON SEAL RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  115. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH 
    1. Install the fender splash shield with the screw.
    2. Fig 34: Installing Fender Splash Shield
      G05276019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  116. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  117. INSTALL ENGINE UNDER COVER NO.1 
    1. Install the 6 bolts, 2 screws, 2 clips and engine under cover.
    2. Fig 35: Locating Engine Under Cover Bolts, Screws And Clips
      G05276018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  118. INSPECT STEERING WHEEL CENTER POINT 
  119. INSPECT IGNITION TIMING (See  ENGINE  ) 
  120. INSPECT ENGINE IDLE SPEED (See  ON-VEHICLE INSPECTION  ) 
  121. INSPECT CO/HC (See  ON-VEHICLE INSPECTION  ) 
  122. CHECK ABS SPEED SENSOR SIGNAL 

    (See TEST MODE PROCEDURE )

  123. PERFORM INITIALIZATION 
    1. Some system need initialization when reconnecting the cable from the battery terminal. (See INITIALIZATION )
  124. INSTALL ENGINE ROOM COVER SIDE 
    1. Install the 5 clips and engine room cover side
      Fig 36: Locating Engine Room Cover Side Clips
      G05276017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  125. INSTALL ENGINE ROOM SIDE LH COVER NO.2 
    1. Fit the clips and install the engine room side LH cover.
    Fig 37: Identifying Engine Room Side Cover
    G05276016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002