Installation

2UR-FSE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

INSTALLATION

1. REMOVE ENGINE FROM ENGINE STAND

(a) Install 2 engine hangers with 2 bolts.
Engine hanger part No.:

Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)

(b) Attach an engine sling device and hang the engine with a chain block.
NOTE: When hanging the engine, make sure to hang the engine with the sling device's hanging angle at 50° or less. If not, the engine or engine hangers may be damaged.

(c) Lift the engine, and remove it from the engine stand.
(d) Place the engine onto a working bench.
2. INSTALL FLYWHEEL SUB-ASSEMBLY

(a) Using SST, hold the crankshaft.
SST: 09213-54015
90119-08216
SST: 09330-00021
(b) Clean the bolts and their installation holes.

(c) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(d) Install the sensor plate and flywheel on the crankshaft.

(e) Uniformly install and tighten the 10 bolts in the sequence shown in the illustration.
Torque: 30 Nm (301 kgf-cm, 22 ft-lbf)
NOTE: Do not strike or damage the flywheel installation bolts. Be sure to handle them carefully.

(f) Mark the upside of each flywheel installation bolt with paint.
(g) Tighten the flywheel installation bolts 90° as shown.
(h) Check that the painted marks are now at a 90° angle to the upside.
NOTE: Do not start the engine for at least 1 hour after the installation.

3. INSTALL INPUT TRANSMISSION DAMPER COVER ASSEMBLY

(a) Install the damper cover with the 9 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)
NOTE: Make sure to insert the clutch disc in the correct direction.

4. INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY Installation

5. INSTALL STARTER HOLE INSULATOR Installation

6. INSTALL OUTLET NO. 1 HYBRID WATER PUMP PIPE

(a) Install the outlet pipe with the 2 bolts.
Torque: 22 Nm (224 kgf-cm, 16 ft-lbf)
7. INSTALL OIL COOLER TUBE SUB-ASSEMBLY Installation

8. INSTALL REAR NO. 2 ENGINE MOUNTING INSULATOR
HINT: Only perform this procedure when replacement of the engine mounting insulator is necessary.

(a) Install the mounting insulator with the 2 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
9. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR
HINT: Only perform this procedure when replacement of the engine mounting insulator is necessary.

(a) Install the 2 mounting insulators with the 4 bolts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
10. INSTALL REAR ENGINE MOUNTING MEMBER
HINT: Only perform this procedure when replacement of the engine mounting insulator is necessary.

(a) Install the mounting member and No. 3 mounting insulator with the 5 nuts.
Torque: 38 Nm (387 kgf-cm, 28 ft-lbf)
11. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

(a) Align the matchmarks on the transfer companion flange and the front propeller shaft.
(b) Temporarily install the front propeller shaft with 6 new bolts and the 2 constant velocity universal joint washers.

(c) Align the matchmarks on the differential companion flange and the front propeller shaft.
(d) Temporarily install the front propeller shaft with 6 new bolts and the 2 constant velocity universal joint washers.

(e) Using a screwdriver or equivalent, hold the transfer companion flange.
(f) Using a 6 mm socket hexagon wrench, tighten the 6 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
NOTE: Be careful not to damage the front propeller shaft.

(g) Using a screwdriver or equivalent, hold the differential companion flange.
(h) Using a 6 mm socket hexagon wrench, tighten the 6 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft-lbf)
NOTE: Be careful not to damage the front propeller shaft.

12. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET LH

(a) Temporarily install the No. 2 mounting bracket with the 2 nuts.

(b) Temporarily install the No. 1 mounting bracket with the 5 bolts.
(c) Tighten the 2 nuts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(d) Remove the 5 bolts and No. 1 mounting bracket.
14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation

15. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

16. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

(a) Install the mounting bracket with the 5 bolts.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
17. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH

(a) Install the mounting bracket with the 5 bolts.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
18. INSTALL FRONT ENGINE MOUNTING INSULATOR

(a) Install the 2 spacers and 2 mounting insulators with the 2 nuts.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
19. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation

20. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation

21. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Apply a light coat of engine oil to a new O-ring.
(b) Install the O-ring to the guide.
(c) Install the dipstick guide with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Install the dipstick.
22. INSTALL FRONT FRAME ASSEMBLY

(a) Slowly lower the engine and set it to the front frame.
(b) Install the 4 nuts.
Torque: 70 Nm (714 kgf-cm, 52 ft-lbf)

(c) Attach the 2 clips and connect the heater wire connector.
23. INSTALL ENGINE AND TRANSMISSION
(a) Place the engine on an engine lifter.
HINT: Place the engine on wooden blocks or equivalent so that the engine is level.

(b) Remove the 2 bolts and 2 engine hangers.
(c) Operate the engine lifter, then install the engine to the vehicle.
NOTE: Make sure that the engine is clear of all wiring and hoses.

(d) Align the front frame to the marks on the vehicle, and temporarily install the front frame with the 4 bolts.
NOTE: Make sure the crossmember is aligned to the vehicle marks as accurately as possible. If not performed accurately, the suspension alignment may become extremely misaligned.

(e) Install the 4 rear engine mounting member's bolts.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)

(f) Tighten the 4 front frame bolts.
Torque: 204 Nm (2080 kgf-cm, 150 ft-lbf)
24. CONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY LH

(a) Connect the absorber and absorber bracket. Then install the bolt.
Torque: 48 Nm (489 kgf-cm, 35 ft-lbf)
25. CONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY RH

(a) Connect the absorber and absorber bracket. Then install the bolt.
Torque: 48 Nm (489 kgf-cm, 35 ft-lbf)
26. CONNECT TRANSMISSION CONTROL SHAFT LEVER

(a) Connect the control shaft lever and spring washer with the nut.
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
27. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
(a) Install the propeller shaft Installation.
28. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install the front exhaust pipe Installation.
29. INSTALL FRONT DRIVE SHAFT ASSEMBLY
(a) Install the drive shaft Installation.
30. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

31. INSTALL NO. 2 AIR DUCT SUB-ASSEMBLY

(a) Attach the 2 claws to install the air duct with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
32. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY
(a) Install the driver side knee airbag Installation.
33. CONNECT HOSES AND CONNECTORS

(a) Attach the 5 clamps and connect the 2 connectors.

(b) Install the heater water pump and bracket with the 2 nuts.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
(c) Connect the heater water pump connector.
(d) Install the inverter cooling pipe bracket with the nut. Then attach the 2 clamps.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)

(e) Connect the 2 oil pump motor controller connectors.
HINT: Refer to the following procedures to connect the oil pump driver connector Installation.

(f) Install the ground wire with the nut.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)

(g) Connect the 3 connectors to the front controller and attach the clamp.

(h) Connect the 2 heater hoses.

(i) Connect the purge line hose.
(j) Connect the No. 5 inverter cooling hose.

(k) Connect the heater wire connector.

(l) Lift up the wiring harness support and connect the 4 ECM connectors.

(m) Install the wiring harness support to the ECM box.
(n) Attach the clip of connector A to the ECM box.
(o) Connect the 4 hybrid vehicle control ECU connectors and 2 wiring harness support connectors.

(p) Install the ECM box cover with the 3 bolts.
Torque: 5.5 Nm (56 kgf-cm, 49 in-lbf)
34. INSTALL WATER PUMP ASSEMBLY WITH MOTOR AND BRACKET Installation

35. CONNECT SUCTION HOSE SUB-ASSEMBLY

(a) Remove the vinyl tape and/or plastic bags from the openings of the disconnected parts and motor compressor.
(b) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the cooler compressor.
Compressor oil:
ND-OIL 11 or equivalent
(c) Install the O-ring on the cooler refrigerant discharge hose.
(d) Connect the cooler refrigerant discharge hose to the cooler compressor with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 87 in-lbf)
37. CONNECT GENERATOR CABLE Installation

38. CONNECT MOTOR CABLE Installation

39. INSTALL INVERTER TERMINAL COVER Installation

40. CONNECT NO. 3 FUEL HOSE Installation

41. CONNECT NO. 1 FUEL HOSE Installation

42. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY Installation

43. INSTALL RESONATOR BRACKET SUB-ASSEMBLY Replacement

44. INSTALL NO. 2 RADIATOR HOSE
45. INSTALL NO. 1 RADIATOR HOSE

46. INSTALL OUTLET ENGINE ROOM ECM DUCT
47. INSTALL RADIATOR RESERVOIR ASSEMBLY Installation

48. INSTALL AIR CLEANER ASSEMBLY RH Installation

49. INSTALL AIR CLEANER ASSEMBLY LH Installation

50. INSTALL INTAKE AIR CONNECTOR PIPE

(a) Align the protrusion of the intake air resonator with the cutout of the bracket and insert the protrusion.
(b) Install the intake air connector pipe with the 3 hose clamps.
for intake air connector pipe and throttle body - Torque: 4.8 Nm (49 kgf-cm, 42 in-lbf)
for intake air connector pipe and air cleaner cap - Torque: 3.8 Nm (39 kgf-cm, 34 in-lbf)
NOTE: Insert the protrusion of the intake air connector pipe into the hole of the hose clamp.
HINT:
- The intake air connector pipe and throttle body clamp can be tightened within the range of 4.0 N*m (41 kgf*cm, 35 in.*lbf) to 5.5 N*m (56 kgf*cm, 49 in.*lbf), and the intake air connector pipe and intake air resonator clamp can be tightened within the range of 2.0 N*m (20 kgf*cm, 18 in.*lbf) to 5.5 N*m (56 kgf*cm, 49 in.*lbf).
- When tightening the hose clamp, make sure the hose clamp's end is within the painted white line (width: 2 mm (0.0787 in.)).

(c) Connect the No. 1 ventilation hose and No. 2 ventilation hose to the intake air connector pipe.
HINT: Position the claws of the clamps as shown in the illustration.

(d) Attach the 2 clips.
HINT: Install the clips so that they are within the hoses' paint marks.

51. INSTALL REAR FRAME SIDE RAIL

(a) Install the 2 side rails with the 6 bolts and 4 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
52. CONNECT FRONT ACTIVE STABILIZER CONTROL ACTUATOR CONNECTOR (w/ Active Stabilizer System) Installation

53. INSTALL INLET ENGINE ROOM ECM DUCT (w/ Active Stabilizer System) Installation

54. INSTALL NO. 3 COOL AIR INTAKE DUCT SUB-ASSEMBLY (w/ Active Stabilizer System) Installation

55. CONNECT FRONT FENDER LINER LH (w/ Active Stabilizer System) Installation

56. INSTALL FRONT BUMPER COVER
(a) Install the front bumper cover Installation.
57. CONNECT OUTLET OIL COOLER HOSE

(a) Using needle-nose pliers, grip the claws of the clip and slide the clip to connect the oil cooler hose.
58. CONNECT INLET OIL COOLER HOSE

(a) Using needle-nose pliers, grip the claws of the clip and slide the clip to connect the oil cooler hose.
59. ADD FRONT DIFFERENTIAL OIL Service and Repair

60. INSTALL FRONT WHEEL
Torque: 140 Nm (1428 kgf-cm, 103 ft-lbf)
61. ADD ENGINE COOLANT Service and Repair

62. ADD ENGINE OIL Replacement

63. INSTALL SERVICE PLUG GRIP Installation

64. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

65. ADD COOLANT (for Inverter) Service and Repair

66. INSPECT FOR COOLANT LEAK (for Inverter) Testing and Inspection

67. CHARGE REFRIGERANT Service and Repair

68. CHECK TRANSMISSION FLUID LEVEL Procedures

69. INSPECT SHIFT LEVER POSITION Adjustments

70. INSPECT FOR OIL LEAK Installation

71. INSPECT FOR COOLANT LEAK Testing and Inspection

72. INSPECT FOR FUEL LEAK Testing and Inspection

73. INSPECT FOR REFRIGERANT LEAK Service and Repair

74. INSPECT FOR EXHAUST GAS LEAK Installation

75. INSPECT IGNITION TIMING Engine

76. INSPECT ENGINE IDLE SPEED Engine

77. INSPECT CO/HC Engine

78. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
79. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
(a) Check and adjust the front wheel alignment Front Wheel Alignment.
80. MEASURE VEHICLE HEIGHT Front Wheel Alignment

81. ADJUST OBJECT RECOGNITION CAMERA Adjustments

82. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR

(a) Install the suspension member protector with the 9 bolts.
for bolt A - Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
for other bolt - Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)
83. INSTALL NO. 1 ENGINE UNDER COVER

(a) Install the under cover with the 13 screws and 7 clips.
84. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH Installation

85. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH Installation

86. INSTALL NO. 2 ENGINE UNDER COVER

(a) Install the under cover with the 4 screws and 2 clips.
87. INSTALL FRONT CENTER FLOOR COVER

(a) Install the floor cover with the 3 screws, 2 bolts and clip.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
88. INSTALL INVERTER COVER ASSEMBLY RH

(a) Install the inverter cover and attach the 2 clips.
89. INSTALL MOTOR CABLE COVER RH

(a) Install the cable cover with the 2 clips.
90. INSTALL COWL TOP VENTILATOR LOUVER RH Installation

91. INSTALL ENGINE ROOM SIDE COVER LH

(a) Install the side cover with the 4 clips.
92. INSTALL ENGINE ROOM SIDE COVER RH

(a) Install the side cover with the 4 clips.
93. CHECK ENGINE COOLANT LEVEL Testing and Inspection

94. INSTALL NO. 1 AIR CLEANER INLET

(a) Align the holes with the connection areas labeled A, and attach the air cleaner inlet.

(b) Install the air cleaner inlet with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
95. INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY

(a) Attach the 4 clips labeled B.
- Make sure the clips are attached securely.
- Attaching the clips forcefully or hitting the top of the clips may damage them.

(b) Install the air cleaner inlet cover with the 5 clips labeled A.
96. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) After sliding the cover from the vehicle front to the rear to attach the 2 clips labeled A, attach the 4 clips labeled B and install the V bank cover.
- Make sure the clips are attached securely.
- Attaching the clips forcefully or hitting the top of the clips may damage them.

97. INSTALL BATTERY SERVICE HOLE COVER LH Battery

98. INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY