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Hybrid Vehicle Transaxle Assembly: Installation

CAUTION:
  • When working on the high voltage systems, always wear insulated gloves.
  • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
  • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.
NOTE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
  1. INSTALL NO. 3 ENGINE MOUNTING BRACKET 
    1. Install the clump in the position shown in the illustration with the 6 bolts.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      Fig 1: Installing Bolts And Clamp
      G04474125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the No. 3 engine mounting bracket with the 3 bolts.

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

      Fig 2: Installing Engine Mounting Bracket
      G04474126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL NO. 6 INVERTER COOLING HOSE 
    1. Connect the inverter cooling hose and install the clamp.
      Fig 3: Installing Inverter Cooling Hose
      G04474127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY 
    1. Install the hybrid vehicle transaxle with the 6 bolts.

      Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 

      NOTE:
      • Ensure that the knock pin is installed on the engine side.
      • Place the HV transaxle in a horizontal position and Align the knock pin and its hole. Then tighten the 6 bolts in the positions shown in the illustration.
      Fig 4: Installing Hybrid Vehicle Transaxle
      G04474128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the housing side cover and starter cover with the 2 bolts.

      Torque: 32 N*m (326 kgf*cm, 23 ft.*lbf) 

      Fig 5: Installing Housing Side Cover And Starter Cover
      G04474129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL NO. 3 ENGINE MOUNTING BRACKET 
    1. Install the engine mounting bracket to the engine mounting insulator with the nut.

      Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) 

  5. REMOVE NO. 1 ENGINE HANGER 
    1. Remove the bolt and engine hanger.
  6. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (See  INSTALLATION  ) 
  7. CONNECT EXHAUST PIPE ASSEMBLY 
    1. Connect the exhaust pipe (See INSTALLATION ).
      Fig 6: Installing Engine Mounting Bracket To Engine Mounting Insulator
      G04474130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL FRONT DRIVE SHAFT ASSEMBLY 
    1. Install the front drive shaft (See INSTALLATION ).
  9. CONNECT NO. 4 INVERTER COOLING HOSE 
    1. Connect the 3 hoses with the 4 clamps.
      Fig 7: Connecting Inverter Cooling Hose With Clamps
      G04474131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. CONNECT CONNECTOR 
    1. Connect the ground wire with the bolt.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      Fig 8: Connecting Ground Wire
      G04474132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 clamps.
      Fig 9: Connecting Clamps
      G04474133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transmission case cover to the hybrid vehicle transaxle with the 3 bolts.

      Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) 

    4. Connect the connector.
      Fig 10: Installing Transmission Case Cover To Hybrid Vehicle Transaxle
      G04474134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the clamps in the 2 locations shown in the illustration.
      Fig 11: Connecting Clamps
      G04474135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the clamp and the 3 connectors shown in the illustration.
  11. INSTALL AIR CLEANER ASSEMBLY 
    1. Install the air cleaner (See INSTALLATION ).
  12. INSTALL INVERTER WITH CONVERTER ASSEMBLY 
    1. Install with inverter converter (see INSTALLATION ).
  13. INSTALL COWL TOP FRONT PANEL SUB-ASSEMBLY OUTER 
    1. Install the cowl top front panel (see INSTALLATION ).
      Fig 12: Connecting Clamp And Connectors
      G04474136Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL FRONT WIPER ARM RH 
    1. Install the front wiper arm (See INSTALLATION ).
  15. INSTALL FRONT WIPER ARM LH 
    1. Install the front wiper arm (See INSTALLATION ).
  16. INSTALL HOOD SUB-ASSEMBLY 
    1. Install the hood (see INSTALLATION ).
  17. ADJUST HOOD SUB-ASSEMBLY 
    1. Adjust the hood (see INSTALLATION ).
  18. INSTALL ENGINE UNDER COVER RH 
  19. INSTALL ENGINE UNDER COVER LH 
  20. INSTALL FRONT WHEEL 
  21. INSTALL SERVICE PLUG GRIP 
    1. Install the service plug grip (See INSTALLATION ).
  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  23. ADD TRANSAXLE OIL 

    Fluid type: Toyota genuine ATF WS 

    Standard capacity: 3.8 liters (4.0 US qts, 3.3 Imp. qts) 

  24. INSPECT TRANSAXLE OIL 
    1. Inspect the transaxle oil (see ON-VEHICLE INSPECTION  ).
  25. ADD COOLANT 
    1. Add the coolant (see COOLANT  ).
  26. CHECK FOR ENGINE COOLANT LEAKAGE 
    1. Check for engine coolant leakage (See ON-VEHICLE INSPECTION ).
  27. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 
    1. Inspect and adjust the front wheel alignment (see FRONT WHEEL ALIGNMENT ).
  28. PERFORM CALIBRATION 
    1. Perform calibration (see CALIBRATION ).
  29. PERFORM INITIALIZATION 
    1. Perform initialization (see INITIALIZATION ).
      NOTE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.
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