ENGINE ASSEMBLY > INSTALLATION

for Preparation Click here

1. Gently place the engine assembly onto wood blocks or equivalent.
   

   NOTICE:

   This step should be done while hanging the engine assembly using the engine hangers and a chain block.

2. Install the flywheel sub-assembly (Click here).
   

1. Gently place the engine assembly onto wood blocks or equivalent.
   

   NOTICE:

   This step should be done while hanging the engine assembly using the engine hangers and a chain block.

2. Install the transmission input damper assembly (Click here).
   

1. Install the hybrid vehicle transaxle assembly (Click here).
   

   NOTICE:

   Be careful not to apply excess force to the transmission input damper assembly when removing or installing the hybrid vehicle transaxle assembly. If excess force is applied, the transmission input damper assembly may be damaged, or its splines may become misaligned.

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

   Torque:

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

1. Install the flywheel housing side cover.
   

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.
   

HINT:

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

1. Position the engine mounting insulator sub-assembly RH as shown in the illustration.
   

2. Temporarily install bolt A to the engine mounting insulator sub-assembly RH.
   

3. Tighten the 3 bolts to the engine mounting insulator sub-assembly RH in the order bolt B, bolt C and bolt A.
   

   Torque:

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

4. Install the 2 cooler brackets with the 2 bolts.
   

   Torque:

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

HINT:

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

1. Install the radiator reservoir tank assembly with the 2 bolts.
   

   Torque:

   5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

HINT:

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

1. Temporarily install bolt A to the engine mounting insulator LH.
   

2. Tighten the 4 bolts to the engine mounting insulator LH in the order bolt C, bolt B, bolt D and bolt A.
   

   Torque:

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

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

1. Set the engine assembly with transaxle on the engine lifter.
   

   NOTICE:

   1. Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
      
   2. Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly.
      

   HINT:

   Place the engine on wooden blocks or equivalent so that the engine is level.

2. Remove the 2 bolts and 2 engine hangers.
   

3. Set the engine assembly with transaxle and front suspension crossmember on an engine lifter.
   

4. Operate the engine lifter to lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulators RH and LH can be installed.
   

   CAUTION:

   Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

   NOTICE:

   1. Make sure that the engine is clear of all wiring and hoses.
      
   2. While raising the engine into the vehicle, do not allow it to contact the vehicle.
      

5. Install the front crossmember with the 4 bolts.
   

   Torque:

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

6. Install the front engine mounting insulator to the front crossmember with the 2 bolts.
   

   Torque:

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

7. 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.

8. Install the engine mounting insulator RH with the bolt and 2 nuts.
   

   Torque:

   Nut A:

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

   Nut B:

   52 N*m{ 530 kgf*cm , 38 ft.*lbf }

   Bolt:

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

9. Tighten the front engine mounting insulator with the bolt and nut.
   

   Torque:

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

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. 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.

1. Install the rear side rail reinforcement sub-assembly RH 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.

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 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 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.

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

   Torque:

   8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

   NOTICE:

   Do not twist the front speed sensor when installing it.

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 (front)	41.5 mm (1.64 in.)
   Minimum (rear)	38.5 mm (1.52 in.)

   HINT:

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

2. Fully insert 2 new gaskets to the exhaust manifold and front exhaust pipe assembly.
   

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

   Text in Illustration 

   *1	Exhaust Manifold and Front Exhaust Pipe Assembly
   *2	Gasket
   *3	Wooden Block

   NOTICE:

   1. Be careful with the installation direction of the gaskets.
      
   2. Do not reuse the gaskets.
      
   3. Do not damage the gaskets.
      
   4. Do not push in the gaskets 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 4 bolts and 4 compression springs.
   

   Torque:

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

6. Connect the 2 heater water hoses.
   

7. Connect the 3 clamps and oxygen sensor connector.
   

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

   Minimum (front)	41.5 mm (1.64 in.)
   Minimum (rear)	38.5 mm (1.52 in.)

   HINT:

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

2. Fully insert 2 new gaskets to the exhaust manifold and front exhaust pipe assembly.
   

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

   Text in Illustration 

   *1	Exhaust Manifold and Front Exhaust Pipe Assembly
   *2	Gasket
   *3	Wooden Block

   NOTICE:

   1. Be careful with the installation direction of the gaskets.
      
   2. Do not reuse the gaskets.
      
   3. Do not damage the gaskets.
      
   4. Do not push in the gaskets 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 4 bolts and 4 compression springs.
   

   Torque:

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

6. Connect the 3 clamps and oxygen sensor connector.
   

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 wire harness with the 2 clamps.
   

2. Install the wire harness with the bolt.
   

3. Connect the wire harness with the 2 clamps.
   

4. Connect the wire harness 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. Using an E8 "TORX" socket wrench, install the 2 stud bolts.
   

   Torque:

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

2. Temporarily install the electric inverter compressor with the bolt and 2 nuts.
   

3. Install the electric inverter compressor with the bolt and 2 nuts.
   

   Torque:

   25 N*m{ 250 kgf*cm , 18 ft.*lbf }

   NOTICE:

   Tighten the bolts in the order shown in the illustration to install the electric inverter compressor.

4. Connect the connector <A> and lock the green-colored lock as shown in the illustration.
   

   CAUTION:

   Wear insulated gloves when performing the procedures.

   Text in Illustration 

   *a	Green-colored Lock

5. Connect the connector <B>.
   

1. Connect the fuel tube connector and fuel pipe.
   

   CAUTION:

   Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.

2. Engage the claw and install the No. 1 fuel pipe clamp.
   

1. Connect the No. 1 fuel vapor feed hose with the clamp.
   

   Text in Illustration 

   *a	FR
   *b	RH

1. Connect the heater hose with the clamp.
   

1. Connect the inlet heater water hose with the clamp.
   

1. Connect the outlet heater water hose with the clamp.
   

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

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

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

1. Connect the No. 2 radiator 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.

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. 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.
   

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

   Standard Oil Grade 

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

   
   

   Standard Capacity 

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

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

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

   NOTICE:

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

1. Check fuel pump operation.
   
   

   1. Connect the intelligent tester to the DLC3.
      

   2. Turn the power switch on (IG).
      

      NOTICE:

      Do not start the engine.

   3. Turn the intelligent tester on.
      

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

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

2. Inspect for fuel leaks.
   
   

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

3. Turn the power switch off.
   

4. Disconnect the intelligent tester from the DLC3.
   

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.
   

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.
   

Torque:

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

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

2. Warm up and stop the engine.
   

3. When using the intelligent tester:
   Check the ignition timing.
   
   

   1. Connect the intelligent tester to the DLC3.
      

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

   3. Turn the intelligent tester on.
      

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

      Standard ignition timing:

      0 to 16 degrees BTDC
      

      NOTICE:

      1. Check the ignition timing with the cooling fans off.
         
      2. Turn off all electrical systems and the A/C.
         
      3. When checking the ignition timing, the shift position neutral (N) or park (P) should be selected.
         

      HINT:

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

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

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

   7. Monitor IGN Advance of the Data List.
      

      Standard ignition timing:

      8 to 12 degrees BTDC
      

      NOTICE:

      When checking the ignition timing, the shift position neutral (N) or park (P) should be selected.

      HINT:

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

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

   9. Turn the power switch off.
      

   10. Turn the intelligent tester off.
       

   11. Disconnect the intelligent tester from the DLC3.
       

4. When not using the intelligent tester:
   
   

   
   
   

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

      Text in Illustration 

      *1

      DLC3

      SST

      09843-18040  
      

      NOTICE:

      1. Be sure to connect the terminals correctly. Failure to do this can damage the engine.
         
      2. Check the ignition timing with the cooling fans off.
         
      3. Turn off all electrical systems and the A/C.
         
      4. When checking the ignition timing, the shift position neutral (N) or park (P) should be selected.
         

   2. Remove the No. 2 cylinder head cover (Click here).
      

   
   
   

   3. Pull out the wire harness shown in the illustration.
      

      NOTICE:

      After checking, wrap the wire harness with tape.

   4. Connect the clip of the timing light to the wire harness.
      

      NOTICE:

      Use a timing light that detects the primary signal.

   5. Inspect the ignition timing at idle.
      

      Standard ignition timing:

      8 to 12 degrees BTDC
      

      NOTICE:

      When checking the ignition timing, the shift position neutral (N) or park (P) should be selected.

      HINT:

      After running the engine at 1000 to 1300 rpm for 5 seconds, check that it returns to idle speed.

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

   7. Inspect the ignition timing at idle.
      

      Standard ignition timing:

      0 to 16 degrees BTDC
      

   8. Confirm that the ignition timing advances when the engine rpm is increased.
      

   9. Remove the timing light.
      

   10. Install the No. 2 cylinder head cover (Click here).
       

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

2. Warm up and stop the engine.
   

3. When using the intelligent tester:
   
   

   1. Connect the intelligent tester to the DLC3.
      

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

   3. Turn the intelligent tester on.
      

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

      HINT:

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

   5. Inspect the engine idle speed.
      

      Standard idle speed:

      950 to 1050 rpm
      

      NOTICE:

      1. Turn all electrical systems and the A/C off.
         
      2. Inspect the idle speed with the cooling fans off.
         
      3. When checking the idle speed, the shift position neutral (N) or park (P) should be selected.
         

   6. Turn the power switch off.
      

   7. Turn the intelligent tester off.
      

   8. Disconnect the intelligent tester from the DLC3.
      

4. When not using the intelligent tester:
   
   

   
   
   

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

      Text in Illustration 

      *1

      DLC3

      SST

      09843-18030  
      

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

   3. Inspect the engine idle speed.
      

      Standard idle speed:

      950 to 1050 rpm
      

      NOTICE:

      1. Turn all electrical systems and the A/C off.
         
      2. Inspect the idle speed with the cooling fans off.
         
      3. When checking the idle speed, the shift position neutral (N) or park (P) should be selected.
         

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

HINT:

This check determines whether or not the idle CO / HC complies with regulations.

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

2. Warm up the engine.
   

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

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

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

   HINT:

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

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

   
   

   1. Check the DTCs (Click here).
      

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

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

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

2. Install the 2 clips.
   

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