HYBRID VEHICLE TRANSAXLE > INSTALLATION

for Preparation Click here

1. Install the motor cable bracket with the bolt.
   

   Torque:

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

1. Install the 2 wire harness clamp brackets with the 2 bolts.
   

   Torque:

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

1. Install the rear engine mounting bracket with the 4 bolts in several steps.
   

   Torque:

   45 N*m{ 459 kgf*cm , 33 ft.*lbf }

   NOTICE:

   Temporarily tighten bolt A, and then fully tighten the 4 bolts in the order of C, B, D and A.

1. Install the front engine mounting bracket with the 3 bolts in several steps.
   

   Torque:

   64 N*m{ 653 kgf*cm , 47 ft.*lbf }

   NOTICE:

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

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

1. Make sure that the knock pins are installed to the engine.
   

   Text in Illustration 

   *1

   Knock Pin

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 }

   NOTICE:

   1. 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.
      
   2. 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.
      
   3. When mounting the hybrid vehicle transaxle to the engine, make sure to securely fit the knock pins into the knock holes.
      
   4. Push in the hybrid vehicle transaxle so that the contact surfaces of the engine and the hybrid vehicle transaxle are aligned evenly.
      
   5. 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).
      
   6. 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.
      

1. Install the engine mounting bracket LH with 3 new bolts in several steps.
   

   Torque:

   64 N*m{ 653 kgf*cm , 47 ft.*lbf }

   NOTICE:

   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 }

   NOTICE:

   When installing the engine mounting insulator, tighten the nut while holding the bolt.

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 }

   HINT:

   Perform this procedure only when replacement of the engine mounting insulator is necessary.

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

   NOTICE:

   1. Make sure to secure the front suspension crossmember sub-assembly to prevent it from dropping.
      
   2. Use the attachments to keep the front suspension crossmember sub-assembly level.
      
   3. 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.
   
   

   
   
   
   
   

   Text in Illustration 

   *1	Front	-	-
   *a	OK	*b	NG

   SST

   09670-00020  
   

   Torque:

   145 N*m{ 1479 kgf*cm , 107 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.
   
   

   
   
   
   

   Torque:

   Bolt A, B, Nut C, D:

   95 N*m{ 969 kgf*cm , 70 ft.*lbf }

   NOTICE:

   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 }

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

1. Install the front crossmember with the 4 bolts.
   

   Torque:

   96 N*m{ 979 kgf*cm , 71 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 }

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

   Torque:

   Bolt A:

   145 N*m{ 1479 kgf*cm , 107 ft.*lbf }

   Bolt B, C :

   93 N*m{ 948 kgf*cm , 69 ft.*lbf }

   NOTICE:

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

HINT:

Perform the same procedure as for the LH side.

1. Install the rear side rail reinforcement sub-assembly LH with the 4 bolts.
   

   Torque:

   96 N*m{ 979 kgf*cm , 71 ft.*lbf }

   NOTICE:

   Temporarily tighten bolts A and B, and then fully tighten the 4 bolts in the order of C, B, D and A.

HINT:

Perform the same procedure as for the LH side.

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

   Torque:

   96 N*m{ 979 kgf*cm , 71 ft.*lbf }

1. Install the flywheel housing side cover.
   

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

   Torque:

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

1. Remove the 2 bolts and 2 engine hangers.
   

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

   NOTICE:

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

HINT:

Perform the same procedure as for the LH side.

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

   NOTICE:

   1. Face the end gap of the front drive shaft hole snap ring downward.
      
   2. Do not damage the transaxle case oil seal.
      
   3. Do not damage the inboard joint boot.
      
   4. Make sure to center the front drive shaft assembly during installation to prevent damage to the front drive shaft hole snap ring.
      

   HINT:

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

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

   Text in Illustration 

   *a

   Matchmark

HINT:

Perform the same procedure as for the LH side.

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 }

HINT:

Perform the same procedure as for the LH side.

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 }

   HINT:

   If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud bolt.

HINT:

Perform the same procedure as for the LH side.

1. 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 }

   NOTICE:

   Further tighten the nut up to 60° if the holes for the clip are not aligned.

2. Install a new clip.
   

HINT:

Perform the same procedure as for the LH side.

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 }

   NOTICE:

   Do not twist the front speed sensor when installing it.

   HINT:

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

HINT:

Perform the same procedure as for the LH side.

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

   HINT:

   1. Be sure to perform this work even when using a new drive shaft.
      
   2. Keep the threaded parts free of oil and foreign matter.
      

2. 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.
   

HINT:

Perform the same procedure as for the LH side.

NOTICE:

When installing the water hose, ensure that the exhaust heat recirculation system is filled with coolant. Otherwise, the engine water pump assembly may be damaged.

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

   Minimum

   41.5 mm (1.64 in.)

   HINT:

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

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

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

   Text in Illustration 

   *1	Exhaust Manifold
   *2	Gasket
   *3	Wooden Block

   NOTICE:

   1. Be careful with the installation direction of the gasket.
      
   2. Do not reuse the gasket.
      
   3. Do not damage the gasket.
      
   4. Do not push in the gasket by using the exhaust pipe when connecting it.
      

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

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

   Torque:

   43 N*m{ 440 kgf*cm , 32 ft.*lbf }

6. Connect the 2 heater water hoses.
   

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

   Minimum

   41.5 mm (1.64 in.)

   HINT:

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

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

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

   Text in Illustration 

   *1	Exhaust Manifold
   *2	Gasket
   *3	Wooden Block

   NOTICE:

   1. Be careful with the installation direction of the gasket.
      
   2. Do not reuse the gasket.
      
   3. Do not damage the gasket.
      
   4. Do not push in the gasket by using the exhaust pipe when connecting it.
      

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

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

   Torque:

   43 N*m{ 440 kgf*cm , 32 ft.*lbf }

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

   Torque:

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

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

1. 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.
   

   Text in Illustration 

   *1	Clip A
   *2	Clip B
   *a	Lip

   NOTICE:

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

1. 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.
   

   Text in Illustration 

   *a

   Matchmark

2. Install the bolt.
   

   Torque:

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

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

2. Install the floor carpet.
   

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. Connect the connector and lock the green-colored lock as shown in the illustration.
   

   CAUTION:

   Wear insulated gloves when performing the procedure.

   Text in Illustration 

   *a	Green-colored Lock

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.
   

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

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

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.
   

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

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

1. 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.
   

1. Temporarily install bolt A to the inverter reserve tank assembly.
   

2. Tighten the 2 bolts to the inverter reserve tank assembly in the order bolt B and bolt A.
   

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

CAUTION:

Wear insulating gloves.

1. Temporarily install the inverter with converter assembly with the 3 bolts.
   

   NOTICE:

   1. 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.
      
   2. To prevent damage, do not hold the inverter with converter assembly by the connectors.
      
   3. 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 }

1. Connect the water hose to the inverter with converter assembly and lock the hose with the retainer.
   

   NOTICE:

   1. Insert the retainer until a click sound is heard.
      
   2. Pull on the hose to confirm that the hose is securely connected.
      
   3. If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.
      

2. Connect the water hose to the inverter with converter assembly and lock the hose with the retainer.
   

   NOTICE:

   1. Insert the retainer until a click sound is heard.
      
   2. Pull on the hose to confirm that the hose is securely connected.
      
   3. If there is foreign matter on the union or the O-ring, clean it with water and finger scouring.
      

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 }

   NOTICE:

   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.
   

CAUTION:

Wear insulating gloves.

1. Remove the 9 bolts and inverter cover.
   

   NOTICE:

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

CAUTION:

Wear insulating gloves.

NOTICE:

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

1. 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 }

   NOTICE:

   Be sure to use a torque wrench to tighten the bolts.

3. Connect the harness clamp.
   

CAUTION:

Wear insulating gloves.

NOTICE:

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

1. 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 }

   NOTICE:

   Be sure to use a torque wrench to tighten the bolts.

3. Connect the harness clamp.
   

CAUTION:

Wear insulating gloves.

NOTICE:

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

1. 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 }

   NOTICE:

   Be sure to use a torque wrench to tighten the bolts.

3. Install the generator cable and cover.
   

   Text in Illustration 

   *a	Align Mark

   NOTICE:

   Close the cover so that the matchmarks are not visible.

CAUTION:

Wear insulating gloves.

NOTICE:

1. Make sure that the interlock is fully engaged.
   
2. Do not allow any foreign objects or water to enter the inverter with converter assembly.
   

1. Temporarily install the frame wire (high voltage cables of the hybrid battery) and 4 bolts to the inverter assembly by hand.
   

   Text in Illustration 

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

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 }

   NOTICE:

   1. Be sure to use a torque wrench to tighten the bolts.
      
   2. Make sure that the interlock are fully engaged.
      

3. Connect the 2 harness clamps.
   

CAUTION:

Wear insulating gloves.

NOTICE:

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

1. Check that each connector and terminal is firmly installed.
   

   NOTICE:

   Make sure that the bolts are fully tightened.

CAUTION:

Wear insulating gloves.

NOTICE:

1. Make sure that the interlock is fully engaged.
   
2. Do not allow any foreign objects or water to enter the inverter with converter assembly.
   

1. Install the inverter cover with the 9 bolts to the inverter with converter assembly.
   

   Text in Illustration 

   *1

   Interlock

   Torque:

   11 N*m{ 112 kgf*cm , 8 ft.*lbf }

NOTICE:

1. Make sure that the connectors are fully engaged.
   
2. 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. Connect the engine wire to the engine room main wire.
   

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

1. 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 }

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

2. Connect the ventilation hose.
   

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.
   

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.
   

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.
   

CAUTION:

Wear insulating gloves.

NOTICE:

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.
   
   

   
   
   
   

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.
   

NOTICE:

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

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

1. Engage the 6 guides.
   

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

1. Install the rear No. 3 floor board.
   

1. Install the rear deck floor box.
   

1. Install the rear No. 2 floor board.
   

1. 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.
   

   Text in Illustration 

   *1	Filler Plug
   *2	Filler Nozzle

   NOTICE:

   1. Stop the vehicle on a level surface.
      
   2. Use Toyota Genuine ATF WS.
      
   3. Be sure to fully insert the filler nozzle into the filler plug opening.
      
   4. 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.
      
   5. Be sure to directly check that the transaxle fluid level is within the specified range.
      
   6. 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.)
   

   NOTICE:

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

NOTICE:

1. Do not reuse the drained coolant because it may contain foreign objects.
   
2. 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. 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.
      

      HINT:

      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]
      

      NOTICE:

      1. Be sure to turn the power switch off before adding SLLC.
         
      2. 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.
      

      HINT:

      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. Add coolant to the full line of the reserve tank.
   

1. Tighten the radiator drain cock plug.
   

2. Add coolant to B line of the reserve tank.
   

   Text in Illustration 

   *1

   B Line

   Standard Capacity:

   Item	Capacity
   Engine coolant	w/ Exhaust Heat Recirculation System: 6.9 liters (7.3 US qts, 6.1 lmp. qts)
   	w/o Exhaust Heat Recirculation System: 6.5 liters (6.9 US qts, 5.7 lmp. qts)

   HINT:

   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).

   NOTICE:

   Never use water as a substitute for engine coolant.

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

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

5. Install the reserve tank cap.
   

6. Bleed air from the cooling system.
   

   NOTICE:

   1. Before starting the engine, turn the A/C switch off.
      
   2. Adjust the heater control to the maximum hot setting.
      
   3. Adjust the blower speed to the low setting.
      
   
   

   1. Warm up the engine until the thermostat opens. While the thermostat is open, allow the coolant to circulate for several minutes. (●1)
      

      HINT:

      The thermostat opening timing can be confirmed by squeezing the inlet radiator hose by hand, and sensing vibrations when the engine coolant starts to flow inside the hose.

      CAUTION:

      When squeezing the radiator hose:

      1. Wear protective gloves.
         
      2. Be careful as the radiator hoses are hot.
         
      3. Keep your hands away from the radiator fans.
         

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

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

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

   Text in Illustration 

   *1	Full Line
   *2	Low Line

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

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

   Text in Illustration 

   *1	Filler Plug

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.)
   

   NOTICE:

   1. Stop the vehicle on a level surface.
      
   2. Be sure to directly check that the transaxle fluid level is within the specified range.
      
   3. Insufficient or excessive amounts of transaxle fluid may damage the hybrid transaxle.
      
   4. 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:

   39 N*m{ 398 kgf*cm , 29 ft.*lbf }

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. 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.
   

   HINT:

   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.
   

CAUTION:

Do not remove the reserve tank cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

NOTICE:

Before performing each inspection, turn the A/C switch off.

1. Remove the reserve tank cap.
   

2. Fill the reserve tank with coolant, and then attach a radiator cap tester.
   

3. Put the engine in inspection mode (Click here).
   

4. Warm up the engine.
   

5. Using a radiator cap tester, increase the pressure inside the radiator to 108 kPa (1.1 kgf/cm², 16 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator, front exhaust pipe assembly, the heater hose around the engine coolant temperature sensor and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
   

6. Remove the radiator cap tester.
   

7. Install the reserve tank cap.
   

Torque:

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

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.
   

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

   
   
   
   
   

   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.)	-	-

1. Horizontally and vertically adjust the hood.
   
   

   
   
   

   1. 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. Adjust the 4 cushion rubbers so that the heights of the hood and fender are aligned.
      

      HINT:

      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. Using a screwdriver, remove the hood lock nut cap.
      

      Text in Illustration 

      *1	Protective Tape

      HINT:

      Tape the screwdriver tip before use.

   
   
   

   2. Loosen the 2 bolts and hood lock bolt.
      

      Text in Illustration 

      *1	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. 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).
      

1. Install the suspension tower damper with the 2 nuts.
   

   Text in Illustration 

   *1	Label
   *a	LH Side
   *b	RH Side

   Torque:

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

   HINT:

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

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.
   

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.
   

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

   Torque:

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

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

   Torque:

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

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

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

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

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

1. Engage the 3 clips to install the cover.
   

   NOTICE:

   1. Be sure to engage the clips securely.
      
   2. Do not apply excessive force or hit the cover to engage the clips. This may cause the cover to break.
      

1. Install the radiator support opening cover with the 9 clips.
   

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

2. Install the 2 clips.