TRANSAXLE CONTROL CABLE ASSEMBLY > INSTALLATION

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1. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY


    C108759

  1. Pull in the control cable to the body.
    Install the 3 bolts.

    Torque:
    5.5 N*m{ 56 kgf*cm , 49 in.*lbf }



2. INSTALL AIR BAG SENSOR ASSEMBLY CENTER

  1. Check that the ignition switch is off.

  1. Check that the battery negative (-) terminal is disconnected.

    CAUTION:
    After disconnecting the negative battery terminal, wait for at least 90 seconds before starting the operation.



    H042717E01

  1. Temporarily install the center airbag sensor assembly with the 3 bolts.

    NOTICE:
    1. If the center airbag sensor assembly has been dropped, or there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one.
    2. When installing the center airbag sensor assembly, be careful that the SRS wiring does not interfere with other parts and that it is not pinched between other parts.

  1. Tighten the 3 bolts to the specified torque.

    Torque:
    17.5 N*m{ 179 kgf*cm , 13 ft.*lbf }

  1. Check that there is no looseness in the installation parts of the center airbag sensor assembly.

  1. Connect the 3 connectors to the center airbag sensor assembly.

  1. Check that the waterproof sheet is properly set.



3. INSTALL AIR DUCT REAR NO.2


4. INSTALL AIR DUCT REAR NO.1


5. INSTALL CONSOLE BOX DUCT NO.1


6. INSTALL SHIFT LEVER


    C116131E02

  1. Install the floor shift assembly with the 4 nuts.

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

    NOTICE:
    Tighten them in the order, A, B, C and D.



    C113140E01

  1. Install the pattern select switch connector, the shift lock control computer connector and the indicator light wire connector.



7. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


  1. In the cabin

    1. Connect the socket of the transmission control cable assembly to the shift lever assembly.



      2. C116180

    2. Turn the socket of the transmission control cable assembly clockwise and install the stopper cap.

      NOTICE:
      Make sure that the transmission control cable assembly (socket) is firmly secured to the shift lever assembly.



      3. C116137E01

    3. Push the stopper cap to the socket as shown in the illustration.



      4. C116138E01

    4. Connect the control cable end to the shift lever assembly.

      NOTICE:
      1. Install the transmission control cable assembly with the graduated cuts to face upward to prevent torsion of the inner cable.
      2. Push the cable end to the bottom of the pin.
      3. Confirm that the connection between the socket and the shift lock control unit is fixed.

  1. Move the shift lever to the N position.



  1. In the engine compartment



      C108758E01

    1. Connect the control cable to the control cable clamp.

  1. Move the control shaft lever to the N position.

  1. Install a new clip to the control bracket.



    C102659E01

  1. Install the control cable to the control bracket.

    NOTICE:
    1. Make sure that the A claws on the clip are securely fit into the bracket holes.
    2. Make sure that the cable is securely installed inside of the B claws of the clip.



    C108745

  1. Temporarily install the control cable to the control shaft lever with the nut.



    C110902E01

  1. Lightly push up the control cable end.

    NOTICE:
    Do not push the control cable end excessively.

  1. Release your hand from the control cable end and then fully tighten the nut.

    Torque:
    15 N*m{ 150 kgf*cm , 11 in.*lbf }



8. INSTALL CONSOLE COVER LOWER


    H042716E01

  1. Connect the connector to the console cover lower.

  1. Install the console cover lower with the 2 screws.



9. INSTALL CONSOLE BOX ASSEMBLY


    B108546E02

  1. Connect each of the clamp and the connector.



    F045693

  1. Keeping the rear console box pulled in the rear direction of the vehicle, install the 6 bolts from the left and right sides.



    B108545E02

  1. Connect the console box lock control cable assembly and install the rear console box.



10. INSTALL CONSOLE BOX HOLE COVER NO.2

HINT:
Use the same procedures for the console box No.2 hole cover and the console box hole cover.



11. INSTALL CONSOLE BOX HOLE COVER


    B112173

  1. Slide the front seat assemblies RH and LH forward.

  1. Slide the rear console box fully to the back end and install the console box hole cover.



12. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER


    B108516

  1. Engage the 2 clips.

  1. Install the 7 screws <C> and the instrument panel finish panel lower center.



13. INSTALL FLOOR CARPET COVER CENTER RH

HINT:
Use the same procedures for the RH side and the LH side.



14. INSTALL FLOOR CARPET COVER CENTER LH


    B108515

  1. Slide the floor carpet cover center LH to the rear of the vehicle, and engage the 2 claws to the instrument panel finish panel lower center at the floor carpet cover center LH.

  1. Install the 2 clips and the floor carpet cover center LH.



15. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY


    B108513E03

  1. Connect the connectors.

  1. Install the 2 bolts <A>, the 2 screws <C>, and the glove compartment door assembly.



16. INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.2


    B112171

  1. Connect the connectors.

  1. Engage the 3 claws and install the instrument panel No.2 under cover sub-assembly.



17. INSTALL COWL SIDE TRIM SUB-ASSEMBLY LH


    B108509

  1. Install the 2 clips and the cowl side trim sub-assembly LH.



18. INSTALL FRONT DOOR SCUFF PLATE LH


    B111782

  1. Connect the connector. (w/ illumination scuff plate)

  1. Engage the 6 claws and 4 clips, and install the front door scuff plate.



19. INSTALL INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY LOWER


    B108587E01

  1. Connect the connectors.

  1. Engage the 5 claws and the 4 clips.

  1. Connect the hood lock control cable assembly.

  1. Install the bolt <A>, the screw <C>, and the instrument panel finish panel sub-assembly lower.



20. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH

HINT:
Use the same procedures for the RH side and the LH side.



21. INSTALL FRONT DOOR SCUFF PLATE RH

HINT:
Use the same procedures for the RH side and the LH side.



22. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER


    B112177

  1. Connect the connectors.

  1. Engage the 2 clips and install the instrument panel finish panel lower.



23. INSTALL CONSOLE PANEL UPPER FRONT


    B112176

  1. Engage the 4 clips and install the console panel upper front.



24. INSTALL SHIFT LEVER KNOB


    C116139

  1. Install the shift lever knob.



25. INSTALL INTAKE AIR SURGE TANK

  1. Install a new gasket to the intake air surge tank.



    A109274E02

  1. Using a socket hexagon wrench 8 mm, install the intake manifold with the 4 bolts and 2 nuts . Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }

  1. Connect the ground cable connector.



    A109273E02

  1. Install the surge tank stay No. 2 (A) with the 2 bolts.

    Torque:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }

  1. Install the surge tank stay No. 1 (B) with the 2 bolts.

    Torque:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }

  1. Install the engine hunger No. 1 (C) with the 2 bolts.

    Torque:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }



    A109268

  1. Connect the ventilation hose.



    A106879E02

  1. Connect the fuel vapor feed hose (A).

  1. Connect the water by-pass hose No.3 (B).

  1. Connect the water by-pass hose No.2 (C).

  1. Connect the throttle motor connector (D).



26. INSTALL EMISSION CONTROL VALVE SET


    A109272E02

  1. Install the emission control valve set with the 2 nuts (A).

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

  1. Connect the fuel vapor feed hose No.2 (B).

  1. Connect the fuel vapor feed hose No.1 (C).

  1. Connect the wire harness clamp (D).

  1. Connect the VSV connector (E).



27. INSTALL INVERTER BRACKET NO.1


    A108713

  1. Install the 4 bolts and inverter bracket.

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

  1. Install the harness clamp and hose clamp.



28. INSTALL W/CONVERTER INVERTER ASSEMBLY
(Click here)


29. ADD COOLANT (Hybrid side)


    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.



30. ADD COOLANT (Engine side)

  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.



31. CHECK FOR COOLANT LEAKS (Hybrid side)


32. CHECK FOR COOLANT LEAKS (Engine side)


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.



33. INSPECT SHIFT LEVER POSITION

  1. Apply the parking brake.

  1. Lock the wheels with chocks to secure the vehicle.

  1. Put the vehicle into the READY-on state.

  1. Move the shift lever to the D position and release the brake pedal.

    NOTICE:
    Be sure to apply the parking brake and lock the wheels with chocks to secure the vehicle.

  1. Slowly move the shift lever to the N position and measure moving distance (A) of the shift lever from the original point to the gear activation point.

    NOTICE:
    Be sure to move the shift lever slowly.

  1. Move the shift lever to the R position and release the brake pedal.

    NOTICE:
    Be sure to apply the parking brake and lock the wheels with chocks to secure the vehicle.

  1. Slowly move the shift lever to the N position and measure moving distance (B) of the shift lever from the original point to the vehicle activation point.

    NOTICE:
    Be sure to move the shift lever slowly.



  1. Check that moving distances (A) and (B) shown in the illustration are almost the same.


    C116133E01

    HINT:
    1. If moving distances (A) and (B) are almost the same, adjustment of the shift lever position is not necessary.
    2. If moving distance (A) is shorter than (B), perform adjustment of the shift lever position [*1].
    3. If moving distance (B) is shorter than (A), perform adjustment of the shift lever position [*2].



34. ADJUST SHIFT LEVER POSITION


  1. If moving distance (A) is shorter than (B) [*1]:


    C116134E01

    HINT:
    If the shift lever is moved from the R to N position, the moving distance of the shift lever from the original point to the gear activation point becomes longer.


    1. Move the shift lever to the N position.



      2. C108753

    2. Loosen the 2 bolts.



      3. C115287

    3. Slightly turn the park/neutral position switch counterclockwise.



      4. C108753E01

    4. Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      13 N*m{ 133 kgf*cm , 10 ft.*lbf }

    5. Recheck the shift lever position.



  1. If moving distance (B) is shorter than (A) [*2]:


    C116135E01

    HINT:
    If the shift lever is moved from the D to N position, the moving distance of the shift lever from the original point to the gear activation point becomes longer.


    1. Move the shift lever to the N position.



      2. C108753

    2. Loosen the 2 bolts.



      3. C115288

    3. Slightly turn the park/neutral position switch clockwise.



      4. C108753E01

    4. Tighten the 2 bolts in the order shown in the illustration.

      Torque:
      13 N*m{ 133 kgf*cm , 10 ft.*lbf }

    5. Recheck the shift lever position.



35. INSPECT SHIFT LEVER OPERATION

  1. While moving the shift lever from the N position to each position, check that the lever moves smoothly and that the shift position indicator comes on properly according to the shift lever position.

  1. Put the vehicle into the READY-on state and check the following:

    1. When the shift lever is moved to the D position, the vehicle moves forward.

    2. When the shift lever is moved to the R position, the buzzer sounds and the vehicle moves in reverse.

      NOTICE:
      The vehicle should not move when the shift position indicator is off.



36. INSTALL ENGINE UNDER COVER NO.1


    A108722

  1. Install the 6 bolts, 2 screws, 2 clips and engine under cover.



37. PERFORM INITIALIZATION
(Click here)