INSTALLATION

Torque:

20 N*m{ 199 kgf*cm , 15 ft.*lbf }

HINT:

It is acceptable for the sensor to be tilted 5°.

Adhesive:

Part No.08833-00080 THREE BOND 1344,

LOCTITE 242 or equivalent.

Torque:

15 N*m{ 153 kgf*cm , 11 ft.*lbf }

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.

Torque:

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

Apply soapy water to the O-ring.

Connect the water inlet pipe to the water inlet.

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 }

Torque:

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

Temporarily install the mounting bracket with the 4 bolts.

Torque:

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

Torque:

54 N*m{ 551 kgf*cm , 40 ft.*lbf }

Torque:

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

Install the 2 bolts and manifold stay No.2.

Torque:

49 N*m{ 500 kgf*cm , 36 ft.*lbf }

Torque:

49 N*m{ 500 kgf*cm , 36 ft.*lbf }

Retighten nuts 1 and 2 shown in the illustration.

Torque:

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

Torque:

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

Install 2 new gaskets to the 2 cylinder heads.

Install the water outlet together with water by-pass hose No.1 and unlock the hose clamp.

Tighten the 2 bolts, 2 nuts and 2 washers.

Torque:

15 N*m{ 153 kgf*cm , 11 ft.*lbf }

Install the clamp.

Connect the engine coolant temperature sensor connector.

Connect the radiator hose inlet.

Torque:

15 N*m{ 153 kgf*cm , 11 ft.*lbf }

Retighten the water outlet mounting bolts and nuts.

Torque:

15 N*m{ 153 kgf*cm , 11 ft.*lbf }

Install the ground cable with the nut.

Torque:

8.4 N*m{ 86 kgf*cm , 74 in.*lbf }

Connect the heater inlet water hose.

Install a new gasket to the intake air surge tank.

Torque:

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

Connect the ground cable connector.

Torque:

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

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

Torque:

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

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

Torque:

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

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

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

Connect the throttle motor connector (D).

Torque:

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

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

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

Connect the wire harness clamp (D).

Connect the VSV connector (E).

Torque:

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

SST

09213-54015   (91651-60855)
09330-00021  

Clean the bolts and bolt holes.

Apply adhesive to 2 or 3 threads of the bolts.

Adhesive:

Part No.08833-00070, THREE BOND 1324 or equivalent

Install the flywheel on the crankshaft.

Torque:

83 N*m{ 846 kgf*cm , 61 ft.*lbf }

NOTICE:

Do not start the engine within 1 hour after installing.

SST

09213-54015   (91651-60855)
09330-00021  

Torque:

30 N*m{ 306 kgf*cm , 22 ft.*lbf }

HINT:

Take care not to insert the transmission input damper in the wrong direction.

Make sure that the knock pins are installed on the engine.

Torque:

Bolt A:

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

Torque:

Bolt B:

46 N*m{ 469 kgf*cm , 34 ft.*lbf }

Torque:

Bolt C:

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

Torque:

Bolt D:

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

NOTICE:

1. Do not reuse bolt B.
   
2. Do not forcibly pry out the hybrid vehicle transaxle assembly
   
3. Do not apply the grease either to the spline or to the input shaft.
   

Torque:

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

Torque:

7.8 N*m{ 80 kgf*cm , 69 in.*lbf }

Install a new drive shaft hole snap ring.

Coat the spline of the inboard joint shaft assembly with ATF.

NOTICE:

1. Set the snap ring with the opening side facing down.
   
2. Be careful not to damage the drive shaft dust cover, boot, or oil seal.
   

Coat the spline of the inboard joint shaft assembly with ATF.

Align the shaft splines and install the drive shaft assembly.

NOTICE:

Be careful not to damage the drive shaft dust cover, boot, or oil seal.

Torque:

32 N*m{ 330 kgf*cm , 24 ft.*lbf }

Torque:

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

Torque:

87 N*m{ 887 kgf*cm , 64 ft.*lbf }

Torque:

75 N*m{ 765 kgf*cm , 55 ft.*lbf }

Torque:

14 N*m{ 138 kgf*cm , 10 ft.*lbf }

Torque:

49 N*m{ 500 kgf*cm , 36 ft.*lbf }

Retighten nuts 1 and 2 shown in the illustration.

Temporarily install the manifold stay to the exhaust manifold and transaxle.

Fully tighten the 2 bolts.

Torque:

34 N*m{ 347 kgf*cm , 25 ft.*lbf }

Torque:

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

Install the engine assembly to the vehicle.

Install the frame side rail plates RH and LH with the 6 bolts and 2 nuts.

Torque:

Bolt A:

85 N*m{ 867 kgf*cm , 63 ft.*lbf }

Bolt B:

32 N*m{ 326 kgf*cm , 24 ft.*lbf }

Nut C:

32 N*m{ 326 kgf*cm , 24 ft.*lbf }

Torque:

Bolt A:

85 N*m{ 867 kgf*cm , 63 ft.*lbf }

Bolt B:

32 N*m{ 326 kgf*cm , 24 ft.*lbf }

Nut C:

32 N*m{ 326 kgf*cm , 24 ft.*lbf }

Torque:

35 N*m{ 360 kgf*cm , 26 ft.*lbf }

Torque:

35 N*m{ 360 kgf*cm , 26 ft.*lbf }

Install the clamp to the steering column hole shield and tighten the bolt (A).

Install the drive shaft assembly LH to the front axle assembly LH.

NOTICE:

1. Be careful not to damage the outboard joint boot.
   
2. Be careful not to damage the speed sensor rotor.
   

Torque:

127 N*m{ 1,300 kgf*cm , 94 ft.*lbf }

Connect the tie rod assembly LH to the steering knuckle with the nut.

Torque:

49 N*m{ 500 kgf*cm , 36 ft.*lbf }

Install a new cotter pin.

NOTICE:

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

Torque:

Bolt A:

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

NOTICE:

1. Be careful not to damage the speed sensor.
   
2. Prevent foreign matter from attaching to the speed sensor.
   
3. Do not twist the sensor wire when installing the speed sensor.
   

Install the flexible hose and the speed sensor to the shock absorber with the bolt and set the clip of sensor on the knuckle.

Torque:

Bolt B:

19 N*m{ 192 kgf*cm , 14 ft.*lbf }

Using a socket wrench (30 mm), install a new axle hub nut.

Torque:

294 N*m{ 3,000 kgf*cm , 217 ft.*lbf }

NOTICE:

Stake the nut after inspecting for looseness and runout in the following steps.

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.

Minimum length:

41.5 mm (1.634 in.)

HINT:

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

Torque:

Bolt:

48 N*m{ 490 kgf*cm , 35 ft.*lbf }

Nut:

56 N*m{ 571 kgf*cm , 41 ft.*lbf }

Connect the heated oxygen sensor connector.

Torque:

56 N*m{ 571 kgf*cm , 41 ft.*lbf }

Connect the heated oxygen sensor connector.

Connect the power steering link connector and clamp.

Install the ground cable.

Install the 2 nuts and pull in the engine wire harness.

Torque:

8.4 N*m{ 85 kgf*cm , 74 in.*lbf }

Connect the engine wire harness to the ECM and the junction block.

Install the body ground and connector.

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

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

Torque:

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

Install the EFI fuel pipe clamp.

Torque:

12 N*m{ 120 kgf*cm , 9 ft.*lbf }

Torque:

6.9 N*m{ 70 kgf*cm , 61 in.*lbf }

Install the control cable and a new clip to the bracket.

Torque:

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

Install the harness clamp and hose clamp.

Temporarily install the compressor and magnetic clutch with the 3 bolts.

Torque:

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

Connect the 2 connectors.

Torque:

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

First tighten bolt A, bolt B, then bolt C in this order.

Torque:

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

Tighten bolt D.

Torque:

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

Torque:

27 N*m{ 275 kgf*cm , 20 ft.*lbf }

Torque:

9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

Connect the clamp.

Torque:

9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

Connect the connector.

Torque:

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

NOTICE:

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

Torque:

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

Torque:

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

Torque:

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

Torque:

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

Torque:

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

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 }

NOTICE:

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

Torque:

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

Torque:

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

Torque:

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

Torque:

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

Torque:

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

Torque:

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

Torque:

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

Torque:

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

Torque:

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

Connect the 2 wire harness clamps to the air cleaner.

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

Torque:

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

Install the 4 clips and cool air intake duct seal.

Torque:

19 N*m{ 194 kgf*cm , 14 ft.*lbf }

Install the battery clamp and battery.

Torque:

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

Push down on the grip to lock.

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).

Remove the 4 shock absorber nuts.

Torque:

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

Install the 4 shock absorber nuts (B).

Torque:

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

Install the wire harness clamp and grommet (A).

Torque:

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

Connect the connector.

Clean the wiper arm serrations.

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

Torque:

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

HINT:

Hold the arm hinge by hand to fasten the nut.

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

Torque:

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

HINT:

Hold the arm hinge by hand to fasten the nut.

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

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

Fill oil.

Transaxle fluid quantity:

4.2 L (4.4 US qts, 3.7 Imp. qts.)

NOTICE:

1. Keep the oil temperature at 5°C (41°F) or higher.
   
2. Stop the vehicle on a flat road.
   
3. Recheck the transaxle oil level after driving when exchanging oil.
   
4. Insufficient or excessive amounts of transaxle oil may be the cause of some trouble.
   

Using a socket hexagon wrench 10 mm, temporarily tighten the filler plug and gasket.

Turn the ignition switch to the ON position.

Select the inspection mode. (Click here)

On the tester, enter the following menus: Powertrain / Hybrid Control / Active test / Inspection Mod 1.

Turn the ignition switch to the ON position and turn the tester on.

HINT:

Operate the oil pump for 1 minute.

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

Fill oil.

NOTICE:

1. Keep the oil temperature at 5°C (41°F) or higher.
   
2. Stop the vehicle on a flat road.
   
3. Recheck the transaxle oil level after driving when exchanging oil.
   
4. Insufficient or excessive amounts of transaxle oil may be the cause of some trouble.
   

Check for leaks if the quantity of oil is low.

Using a socket hexagon wrench 10 mm, install the filler plug, and a new gasket.

Torque:

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

Connect the intelligent tester to the DLC3.

Turn the ignition switch to the ON position and turn the intelligent tester on.

NOTICE:

Do not start the engine.

Select the Active Test mode on the intelligent tester to operate the fuel pump.

HINT:

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

Check that there are no fuel leaks anywhere in the fuel system after performing maintenance.

NOTICE:

Insert one end of the hose into the reserve tank.

Add coolant from the reserve tank.

Coolant quantity:

3.4 L (3.6 US qts, 3.0 Imp. qts.)

When using the intelligent tester:

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.

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.

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

Tighten the lower drain plug of the radiator.

Loosen the upper drain plug of the radiator.

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

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.
   

Install the radiator cap securely.

Fill the radiator reservoir tank with coolant.

Warm up the engine.

HINT:

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

Stop the engine and wait until the coolant cools down.

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

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.

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

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

Warm up the engine.

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.

Install the 2 bolts and engine under cover No.2.

Set the vehicle to inspection mode (Click here).

Warm up the engine.

When using the intelligent tester:

1. Connect the intelligent tester (with CAN VIM) to the DLC3.
   

2. Enter DATA LIST MODE on the intelligent tester.
   

   Ignition timing:

   8 to 12° BTDC
   

   NOTICE:

   1. Turn all the electrical systems off.
      
   2. Inspect the engine idle speed with the cooling fan off.
      

   HINT:

   Refer to the intelligent tester operator's manual if you need help to select DATA LIST.

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

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

   SST

   09843-18040  
   

   NOTICE:

   1. Make sure of the terminal numbers before connecting them. Connection with a wrong terminal can damage the engine.
      
   2. Turn off all electrical systems before connecting the terminals.
      
   3. Perform this inspection after the cooling fan motor is turned off.
      

2. Pull out the red-colored wire harness as shown in the illustration.
   

3. Connect the tester terminal of the timing light to the engine.
   

   NOTICE:

   Use a timing light which detects the first signal.

4. Inspect ignition timing at idle.
   

   Ignition timing:

   8 to 12° BTDC
   

   NOTICE:

   When checking the ignition timing, the transmission is in neutral.

   HINT:

   Run the engine at 1,000 to 1,300 rpm for 5 seconds, check that the engine rpm returns to idle speed.

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

6. Inspect ignition timing at idle.
   

   Ignition timing:

   7 to 24° BTDC
   

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

8. Remove the timing light.
   

Set the vehicle to inspection mode (Click here).

Warm up the engine.

Connect the intelligent tester (with CAN VIM) to the DLC3.

Enter DATA LIST MODE on the intelligent tester.

Idle speed:

850 to 950 rpm.

NOTICE:

1. When checking the idle speed, the transmission is in neutral.
   
2. Check the idle speed with the cooling fan off.
   
3. Switch off all accessories and air conditioning before connecting the intelligent tester.
   

HINT:

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

Set the vehicle to inspection mode (Click here).

Start the engine.

Run the engine at 2,500 rpm for approximately 180 seconds.

Check CO/HC concentration at idle and/or 2,500 rpm.

HINT:

When doing the 2 mode (with the engine is in the idle and 2,500 rpm) test, the measuring procedures are prescribed by the applicable local regulations.

1. Check heated oxygen sensor operation (Click here).
   

2. Check heated air fuel ratio sensor operation (Click here).
   

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

   CO	HC	Problems	Causes
   Normal	High	Rough idle	Faulty ignitions: Incorrect timing Fouled, shorted or improperly gapped plugs Incorrect valve clearance Leaks in intake and exhaust valves Leaks in cylinders
   Low	High	Rough idle (Fluctuating HC reading)	Vacuum leaks: PCV hoses Intake manifold Throttle body Brake booster line Lean mixture causing misfire
   High	High	Rough idle (Black smoke from exhaust)	Restricted air filter Plugged PCV valve Faulty EFI systems: Faulty pressure regulator Defective water temperature sensor Defective mass air-flow meter Faulty ECM Faulty injectors Faulty throttle position sensor

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