Repair Procedures: Removal: Installation

After installing the engine clutch assembly (B), install the snap ring (A).

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To obtain suitable engine clutch end play, measure the height between A and B as indicated below and select spacer of suitable thickness by referring to the table below.

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A - B = C [in.(mm)]	Part Number	Spacer Thickness [in.(mm)]
C = 0.0386(0.980) to 0.0421(1.070)	45849-3D902	0.0354(0.90)
C = 0.0421(1.070) to 0.0457(1.160)	45849-3D992	0.0390(0.99)
C = 0.0457(1.160) to 0.0492(1.250)	45849-3D082	0.0425(1.08)
C = 0.0492(1.250) to 0.0528(1.340)	45849-3D172	0.0461(1.17)
C = 0.0528(1.340) to 0.0563(1.430)	45849-3D262	0.0496(1.26)
C = 0.0563(1.430) to 0.0598(1.520)	45849-3D352	0.0531(1.35)
C = 0.0598(1.520) to 0.0634(1.610)	45849-3D442	0.0567(1.44)
C = 0.0634(1.610) to 0.0669(1.700)	45849-3D532	0.0602(1.53)
C = 0.0669(1.700) to 0.0705(1.790)	45849-3D622	0.0638(1.62)
C = 0.0705(1.790) to 0.0740(1.880)	45849-3D712	0.0673(1.71)
C = 0.0740(1.880) to 0.0776(1.970)	45849-3D802	0.0709(1.80)
C = 0.0776(1.970) to 0.0811(2.060)	45849-3D802	0.0744(1.89)
C = 0.0811(2.060) to 0.0846(2.150)	45849-3D982	0.0780(1.98)
C = 0.0846(2.150) to 0.0882(2.240)	45849-3D072	0.0815(2.07)
C = 0.0882(2.240) to 0.0917(2.330)	45849-3D162	0.0850(2.16)
C = 0.0917(2.330) to 0.0953(2.420)	45849-3D252	0.0886(2.25)

Install the spacer (A).

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Remove the residual sealant from the contacting area of motor assembly and automatic transaxle.
NOTE:
- Be careful not to scratch the contacting area when removing sealant.
- Perform procedure after taping the area to prevent residual sealant from entering automatic transaxle motor housing.
Apply grease to inner surface (A) of automatic transaxle motor housing.
Recommended Grease Grade : CASMOLY L9508, KLUBER 9R100 or equivalent

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Apply sealant on the motor housing side.
Recommended Grease Grade : LOCTITE FMD-546, THREE-BOND TB1281B or equivalent

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NOTE:
- Wipe off the motor housing surface before applying sealant.
- Apply sealant inside the bolt holes.
Install motor removal/installation tool (09365-3D630) to the motor assembly.

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By using a jack, install the motor assembly (A) to automatic transaxle (B).

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NOTE: To prevent damaging the o-ring, slowly lower the motor assembly onto the automatic motor housing while maintaining horizontality.
Remove the motor removal/installation tool (09365-3D630) from the motor assembly.
After installing the rotor rotating tool (09365-3D400) to spline, align the engine clutch spline by rotating it by 1 notch.

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Remove the motor removal/installation guide (09450-3D200).
Tighten the motor assembly mounting bolts.
Tightening Torque:

19.6 - 25.5 N.m (2.0 - 2.6 kgf.m, 14.5 - 18.8 lb.ft)

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To measure the engine clutch end play, install the end play measuring jig (09365-3D900).

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After installing the dial gauge above the end play measuring jig (09365-3D900), pull the spline (A) to measure the end play.
End Play : 0.05 - 0.20 mm

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NOTE: If the measured value of end play is out of specification, remove the motor assembly again and replace with a spacer of suitable thickness. (Refer to step 4).
Perform ATF leak test.
(Refer to Hybrid Drive Motor Assembly - " TEST ")
By using the oil seal installer (09365-3D500, 09231-H1100), install the motor oil seal.

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NOTE: Install by using a rubber hammer being careful not to impact the motor assembly.
Install the automatic transaxle
(Refer to Automatic Transaxle System - " AUTOMATIC TRANSAXLE ")
Perform TCM learning procedure.
(Refer to Automatic Transaxle System - " AUTOMATIC TRANSAXLE CONTROL SYSTEM ")