THERMOSTAT > INSTALLATION

for Preparation Click here



1. INSTALL THERMOSTAT


    A080298E01

  1. Install a new gasket to the thermostat.

  1. Align the jiggle valve of the thermostat and water inlet, and insert the thermostat in the water inlet housing.

    HINT:
    The jiggle valve should be set within +-15° from the prescribed position.



2. INSTALL WATER INLET


    A080824

  1. Install the 3 nuts and the water inlet with the 3 nuts.

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



3. INSTALL WATER INLET PIPE


    A080823

  1. Install a new O-ring to the water inlet pipe.

  1. Apply soapy water to the O-ring.

  1. Connect the water inlet pipe to the water inlet.

  1. Install the bolt which is used to fix the water inlet pipe to the cylinder head with the bolt.

    Torque:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }



4. INSTALL W/CONVERTER INVERTER ASSEMBLY

CAUTION:
Wear insulating gloves.



    A109653

  1. Install the w/ converter inverter assembly with the 2 nuts and bolt.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

    NOTICE:
    2 people are needed to install the w/ converter inverter assembly.



5. INSTALL INVERTER BRACKET NO.4


    A109652

  1. Install the inverter bracket No.4 with the 2 bolts.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }



6. INSTALL ENGINE ROOM RELAY BLOCK ASSEMBLY


    A109651E01

  1. Install the engine room relay block assembly.



7. REMOVE INVERTER COVER


    A109654

  1. Remove the 2 bolts and inverter cover to the w/ converter inverter assembly.



8. CONNECT NO.3 WIRE FRAME

CAUTION:
Wear insulating gloves.

NOTICE:
  1. Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly. (Click here)
  2. Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.



    A109800E01

  1. After connecting the connector, press the lever down to connect the No.3 wire frame and install the bolt to the w/ converter inverter assembly.

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



    A108521

  1. Connect the No.3 wire frame (high voltage cable of the rear motor) with the 5 bolts to the w/ converter inverter assembly.

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



9. CONNECT MG ECU CONNECTOR

CAUTION:
Wear insulating gloves.

NOTICE:
  1. Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly. (Click here)
  2. Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.



    A108518

  1. Connect the 2 connectors and 2 grommets to the w/ converter inverter assembly.



10. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR

CAUTION:
Wear insulating gloves.

NOTICE:
  1. Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly. (Click here)
  2. Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.



    A108520

  1. Connect the high voltage cable of the Generator with the 5 bolts to the w/ converter inverter assembly.

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



    A108519

  1. Connect the high voltage cable of the Motor with the 5 bolts to the w/ converter inverter assembly.

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



11. CONNECT ENGINE WIRE NO.4

CAUTION:
Wear insulating gloves.

NOTICE:
  1. Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly. (Click here)
  2. Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.



    A108517E01

  1. Connect the engine wire No.4 with the connector, clamp and grommet to the w/ converter inverter assembly.

  1. Connect the engine wire No.4 with the bolt to the w/ converter inverter assembly.

    Torque:
    5.4 N*m{ 55 kgf*cm , 48 in.*lbf }



12. CHECK HIGH VOLTAGE CABLE CONNECTION

CAUTION:
Wear insulating gloves.

NOTICE:
  1. Make sure that the inverter converter is temporarily installed before working on the converter inverter assembly. (Click here)
  2. Do not allow any foreign objects or waterdrops to enter the w/ converter inverter assembly.



    A108527

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

    NOTICE:
    1. Make sure that the connectors are fully engaged.
    2. Make sure that the bolts are fully tightened.



13. INSTALL INVERTER COVER


    A108515

  1. Install the inverter cover with the 12 bolts to the w/ converter inverter assembly.

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



    A108511E01

  1. Install the interlock bracket with the bolt to the w/ converter inverter assembly.

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



14. INSTALL POWER STEERING ECU BRACKET


    A108514

  1. Install the power steering ECU bracket with the bolt to the w/ converter inverter assembly.

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



15. CONNECT WATER HOSE


    A108516

  1. Connect the water hose with the clamp to the w/ converter inverter assembly.



16. INSTALL INVERTER RESERVE TANK SUB-ASSEMBLY


    A108513

  1. Connect the 2 water hoses with the 2 clamps to the inverter reserve tank sub-assembly.



    A108512

  1. Install the inverter reserve tank with the 2 bolts to the w/ converter inverter assembly.

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



17. CONNECT ENGINE ROOM WIRE NO.2


    A108525E01

  1. Connect the engine room wire No.2 with the nut.

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



18. CONNECT CIRCUIT BREAKER SENSOR NO.1


    A109507

  1. Connect the circuit breaker sensor No.1 connector.



19. INSTALL POWER STEERING ECU ASSEMBLY


    C112235

  1. Install the power steering ECU assembly with the 2 bolts.

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



    C112234

  1. Connect the 2 wire harness clamps to the power steering ECU assembly.



    C108541

  1. Connect the 2 power steering ECU assembly connectors and securely lock the connectors.



    C108539

  1. Install the ground cable terminal to the power steering ECU assembly with the bolt.

    Torque:
    6.0 N*m{ 61 kgf*cm , 53 in.*lbf }



20. INSTALL INVERTER BRACKET NO.5


    C111474

  1. Install the inverter bracket No.5 with the bolt.

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



21. INSTALL AIR CLEANER W/RESONATER


    A109267

  1. Install the air cleaner hose No.1 to the throttle body assembly with the hose clamp.



    A106878

  1. Install the air cleaner case w/ resonator with the 5 bolts.

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



    A109270

  1. Connect the MAF meter connector.

  1. Connect the 2 wire harness clamps to the air cleaner.



    A109893

  1. Connect the ventilation hose No.2.



22. INSTALL AIR CLEANER CAP W/INLET

  1. Install the air cleaner filter element to the air cleaner case.



    A108124

  1. Install the 2 bolts, 4 clamps and air cleaner cap w/ inlet.

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



23. INSTALL COOL AIR INTAKE DUCT SEAL

  1. Install the 4 clips and cool air intake duct seal.



24. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER

  1. Remove the 4 shock absorber nuts.



    A112528E01

  1. Install the 4 bolts, 2 nuts and cowl top panel sub-assembly.

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

  1. Install the 4 shock absorber nuts (B).

    Torque:
    80 N*m{ 815 kgf*cm , 59 ft.*lbf }

  1. Install the wire harness clamp and grommet (A).



25. INSTALL WINDSHIELD WIPER LINK ASSEMBLY


    E110471

  1. Install the windshield wiper motor and link assembly with the 5 bolts.

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

  1. Connect the connector.



26. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY


27. INSTALL FRONT WIPER AND BLADE ASSEMBLY ARM LH


    B108016E03

  1. Operate the front wiper, and stop the front wiper motor at the automatic stop position.

  1. Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).



    E069045E01

  1. Install the front wiper arm and blade assembly LH with the nut at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.



28. INSTALL FRONT WIPER AND BLADE ASSEMBLY ARM RH


    B108016E03

  1. Clean the wiper arm serrations.

  1. Clean the wiper pivot serrations with a wire brush (when reinstalling).



    E069046E01

  1. Install the front wiper arm and blade assembly RH with the 2 nuts at the position as shown in the illustration.

    Torque:
    24 N*m{ 245 kgf*cm , 18 ft.*lbf }

    HINT:
    Hold the arm hinge by hand to fasten the nut.

  1. Operate the front wipers while spraying water or washer fluid on the windshield.

  1. Make sure that the wipers function properly and there is no interference with the vehicle body.



29. INSTALL SERVICE PLUG GRIP

NOTICE:
Before connecting the service plug, check that no parts and tools remain and that the high voltage terminals and connectors are connected securely.



    A115547

  1. Wear insulation gloves, then insert the service plug.

  1. Push down on the grip to lock.

  1. Close the battery service hole cover.

    NOTICE:
    Check that the 2 battery service hole cover clips are securely connected to the battery carrier bracket (click sound).



30. REMOVE ENGINE ROOM COVER SIDE


    A109835

  1. Install the 5 clips and engine room cover side



31. INSTALL ENGINE ROOM SIDE LH COVER


    A108719

  1. Fit the clips and install the engine room side LH cover.



32. CONNECT BATTERY NEGATIVE CABLE


33. ADD HYBRIT VEHICLE COOLANT


    C109302

  1. Loosen the bleeder plug shown in the illustration and connect a hose.

    NOTICE:
    Insert one end of the hose into the reserve tank.

  1. Add coolant from the reserve tank.



    C109303E01

  1. Add coolant until the level of coolant in the hose attached to the bleeder plug reaches the same level as the FULL line of the reserve tank.

    Coolant quantity:
    3.4 L (3.6 US qts, 3.0 Imp. qts.)



  1. When using the intelligent tester:



      E109221E03

    1. Connect the intelligent tester to the DLC3.

    2. Turn the ignition switch to the ON position.

    3. Select the inspection mode (Click here).

    4. On the tester, enter the following menus: Powertrain / Hybrid Control / Active test / Water Pump.

    5. Keep the coolant at the FULL level in the reserve tank to compensate for the drop in coolant level when the air bleeds.

      Standard:
      Air bleeding from the coolant system is completed when the noise made by the water pump becomes smaller and the circulation of coolant in the reserve tank improves.

      HINT:
      Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the coolant system.

  1. When not using the intelligent tester:

    1. Put the vehicle into the READY-on state. [*1]

    2. Turn the ignition switch off and add coolant to the FULL level because the coolant level drops as the air bleeds. [*2]

      NOTICE:
      1. Be sure to turn the ignition switch off before adding LLC.
      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 coolant system is completed.

      Standard:
      Air bleeding from the coolant system is completed when the noise made by the water pump becomes smaller and the circulation of coolant in the reserve tank improves.

      HINT:
      Loud noise made by the water pump and poor circulation of coolant in the reserve tank indicates that there is air in the coolant system.

  1. When the air is completely bled from the coolant system, tighten the plug.



    C109304

  1. Add coolant to the FULL mark of the reserve tank.



34. ADD ENGINE COOLANT

  1. Tighten the lower drain plug of the radiator.

  1. Loosen the upper drain plug of the radiator.



    A080492E01

  1. Install a vinyl tube to the vent plug located on the upper drain plug.

  1. Fill the radiator with engine coolant until the vinyl tube is filled with the coolant.

  1. Tighten the upper drain plug.

    CAUTION:
    1. Do not use an alcohol type coolant or plain water alone.
    2. The coolant must be mixed with plain water (preferably de-mineralized water).

      Capacity:
      9.7 liters (10.3 US qts, 8.5 lmp.qts)

    HINT:
    1. Improper coolants may damage engine cooling system.
    2. Use "Toyota Long Life Coolant" or equivalent. Mix it with plain water according to the manufacturer's instruction.
    3. Using of coolant which includes more than 50% (freezing protection down to -35°C (-31°F) or 60% (freezing protection down to -50°C (-58°F) of ethylene-glycol is recommended but not more than 70%.
    4. Observe the coolant level inside the radiator by pressing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add the coolant.

  1. Install the radiator cap securely.

  1. Fill the radiator reservoir tank with coolant.

  1. Warm up the engine.

    HINT:
    Press the inlet and outlet radiator hoses several times by hand while warming up the engine.

  1. Stop the engine and wait until the coolant cools down.

  1. Remove the radiator cap and check the coolant level inside the radiator.

  1. If the coolant level is below the full level, perform the steps from (a) through (j) and repeat the operation until the coolant level stays the full level.

  1. Recheck the coolant level inside the radiator reservoir tank. If it is below the full level, add the coolant.



35. CHECK HYBRID VEHICLE COOLANT LEAKS


36. CHECK FOR ENGINE COOLANT LEAKS


A078989

CAUTION:
Do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

  1. Fill the radiator with coolant and attach a radiator cap tester.

  1. Warm up the engine.

  1. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm, 17 psi), and check that the pressure does not drop.
    If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.



37. PERFORM INITIALIZATION

  1. Some system need initialization when reconnecting the battery cable. (Click here)