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Hybrid Vehicle Transaxle Assembly: Removal

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. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  2. REMOVE SERVICE PLUG GRIP 
    1. Remove the service plug grip (See REMOVAL ).
  3. REMOVE FRONT WHEEL 
  4. REMOVE ENGINE UNDER COVER LH 
  5. REMOVE ENGINE UNDER COVER RH 
  6. DRAIN COOLANT 
    1. Drain the coolant (see COOLANT  ).
  7. DRAIN TRANSAXLE OIL 
    1. Drain the transaxle oil (see ON-VEHICLE INSPECTION  ).
  8. REMOVE HOOD SUB-ASSEMBLY 
    1. Remove the hood (see REMOVAL ).
  9. REMOVE FRONT WIPER ARM LH 
    1. Remove the front wiper arm LH (see REMOVAL ).
  10. REMOVE FRONT WIPER ARM RH 
    1. Remove the front wiper arm RH (see REMOVAL ).
  11. REMOVE COWL TOP FRONT PANEL SUB-ASSEMBLY OUTER 
    1. Remove the cowl top front panel (see REMOVAL ).
  12. REMOVE INVERTER WITH CONVERTER ASSEMBLY 
    1. Remove the inverter with converter (See REMOVAL ).
  13. REMOVE AIR CLEANER ASSEMBLY 
    1. Remove the air cleaner (see REMOVAL ).
  14. DISCONNECT WIRE HARNESS 
    1. Disconnect the 3 connectors shown in the illustration and the clamp.
      Fig 1: Disconnecting Wire Harness Connectors
      G04474112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 clamps shown in the illustration.
      Fig 2: Disconnecting Wire Harness Clamps
      G04474113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector.
    4. Remove the 3 bolts and transmission case cover from the hybrid vehicle transaxle.
      Fig 3: Removing Transmission Case Cover From Hybrid Vehicle Transaxle
      G04474114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the 2 clamps.
      Fig 4: Disconnecting Clamps
      G04474115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the bolt and ground wire.
      Fig 5: Removing Ground Wire
      G04474116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT NO. 4 INVERTER COOLING HOSE 
    1. Remove the 4 clamps and disconnect the 3 hoses.
  16. REMOVE FRONT DRIVE SHAFT ASSEMBLY 
    1. Remove the front drive shaft (see REMOVAL ).
  17. DISCONNECT EXHAUST PIPE ASSEMBLY 
    1. Disconnect the exhaust pipe (See REMOVAL ).
  18. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (See  REMOVAL  ) 
    Fig 6: Removing Inverter Cooling Hose Clamp
    G04474117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. SUSPEND ENGINE ASSEMBLY 
    1. Disconnect the 2 PCV hoses.
    2. Install the No. 1 and No. 2 engine hangers in the correct direction.

      Parts No.: 

      No. 1 engine hanger: 12281--22021 

      No. 2 engine hanger: 12281--15040 

      Bolt: 91512-B1016 

      Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

      Fig 7: Identifying Engine Hangers Position
      G04474118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Attach an engine chain hoist to the engine hangers.
      CAUTION: Do not attempt to hang the engine by hooking the chain to any other parts.
  20. SUPPORT HYBRID VEHICLE TRANSAXLE ASSEMBLY 
    1. Using a transmission jack, support the hybrid vehicle transaxle.
  21. DISCONNECT NO. 3 ENGINE MOUNTING BRACKET 
    1. Remove the nut and disconnect the engine mounting bracket from the engine mounting insulator.
      Fig 8: Removing Engine Mounting Bracket From Engine Mounting Insulator
      G04474119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY 
    1. Remove the 2 bolts, starter cover and housing side cover.
      Fig 9: Removing Starter Cover And Housing Side Cover
      G04474120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 bolts and hybrid vehicle transaxle.
      NOTE: To avoid damage to the knock pin, do not pry the connecting portion of the HV transaxle and the engine.
      Fig 10: Removing Hybrid Vehicle Transaxle
      G04474121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 6 INVERTER COOLING HOSE 
    1. Remove the clamp and inverter cooling hose.
      Fig 11: Removing Inverter Cooling Hose
      G04474122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE NO. 3 ENGINE MOUNTING BRACKET 
    1. Remove the 3 bolts and engine mounting bracket.
      Fig 12: Removing Engine Mounting Bracket
      G04474123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 bolts shown in the illustration and clamp.
      Fig 13: Removing Bolts And Clamp
      G04474124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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