Hybrid Transaxle Assembly

Hybrid Vehicle Transaxle Assembly:

HYBRID VEHICLE TRANSAXLE ASSY
REPLACEMENT

NOTICE:
^ When working on the high voltage systems, always wear insulated gloves.
^ After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
^ 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.

1. DISCONNECT BATTERY NEGATIVE TERMINAL
2. REMOVE SERVICE PLUG GRIP
3. REMOVE FRONT WHEELS
4. REMOVE ENGINE UNDER COVER LH
5. REMOVE ENGINE UNDER COVER RH
6. DRAIN COOLANT
7. DRAIN TRANSAXLE OIL
8. REMOVE HOOD SUB-ASSY
9. REMOVE FR WIPER ARM RH
10. REMOVE FR WIPER ARM LH
11. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT
12. REMOVE W/CONVERTER INVERTER ASSY
13. REMOVE AIR CLEANER ASSY
14. DISCONNECT WIRE HARNESS

a. Disconnect the 3 connectors shown in the illustration and the clamp.

b. Separate the 2 clamps shown in the illustration.

c. Disconnect the connector.
d. Remove the 3 bolts and the transmission case cover from the hybrid vehicle transaxle.

e. Disconnect the 2 clamps.

f. Remove the bolt and the earth wire.

15. SEPARATE INVERTER COOLING HOSE NO.4
a. Remove the 4 clamps and disconnect the 3 hoses.
16. REMOVE FRONT DRIVE SHAFT ASSY LH
17. REMOVE FRONT DRIVE SHAFT ASSY RH
SST 09520-01010, 09520-24010 (09520-32040)
18. SEPARATE EXHAUST PIPE ASSY
19. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSY

20. SUSPEND ENGINE ASSY
a. Disconnect the 2 PCV hoses.
b. 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 Nm (387 kgf-cm, 28 ft. lbs.)
c. Attach the engine chain hoist to the engine hangers.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other parts.

21. SUPPORT HYBRID VEHICLE TRANSAXLE ASSY
a. Using a transmission jack, support the hybrid vehicle transaxle assy.

22. SEPARATE ENGINE MOUNTING BRACKET NO.3
a. Remove the nut and disconnect engine mounting bracket No.3 from the engine mounting insulator.
23. REMOVE HYBRID VEHICLE TRANSAXLE ASSY

a. Remove the 2 bolts, starter cover and housing side cover.

b. Remove the 6 bolts and hybrid vehicle transaxle assy.

NOTICE: To avoid damage to the knock pin, do not pry the connecting portion of the HV transaxle assy and the engine.

24. REMOVE INVERTER COOLING HOSE NO.6
a. Remove the clamp and inverter cooling hose No.6.
25. REMOVE ENGINE MOUNTING BRACKET NO.3

a. Remove the 3 bolts and engine mounting bracket No.3.

b. Remove the 6 bolts and stay shown in the illustration.
26. INSTALL ENGINE MOUNTING BRACKET NO.3

a. Install the stay in the position shown in the illustration using 6 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

b. Install engine mounting bracket No.3 using 3 bolts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)

27. INSTALL INVERTER COOLING HOSE NO.6
a. Connect the inverter cooling hose No.6 and install the clamp.
28. INSTALL HYBRID VEHICLE TRANSAXLE ASSY

a. Install the hybrid vehicle transaxle assy with 6 bolts.
Torque: 33 Nm (337 kgf-cm, 24 ft. lbs.)

NOTICE:
^ Ensure that the knock pin is installed on the engine side.
^ Tighten the 6 bolts in the positions shown in the illustration by placing the HV transaxle assy in a horizontal position and aligning the knock pin and its hole.

b. Install the housing side cover and starter cover with the 2 bolts.
Torque: 32 Nm (326 kgf-cm, 23 ft. lbs.)

29. CONNECT ENGINE MOUNTING BRACKET NO.3
a. Connect the engine mounting bracket No.3 to the engine mounting insulator using a nut.
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
30. REMOVE ENGINE HANGER NO.1
a. Remove the bolt and engine hanger.
31. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY
SST 09670-00010
32. CONNECT EXHAUST PIPE ASSY
33. INSTALL FRONT DRIVE SHAFT ASSY LH
34. INSTALL FRONT DRIVE SHAFT ASSY RH

35. CONNECT INVERTER COOLING HOSE NO.4
a. Connect the 3 hoses with the 4 clamps.
36. CONNECT CONNECTOR

a. Connect the earth wire using a bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

b. Connect the 2 clamps.

c. Install the transmission case cover to the hybrid vehicle transaxle using the 3 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
d. Connect the connector.

e. Connect the clamps in the 2 locations shown in the illustration.

f. Connect the clamp and the 3 connectors shown in the illustration.
37. INSTALL AIR CLEANER ASSY
38. INSTALL W/CONVERTER INVERTER ASSY
39. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT
40. INSTALL FR WIPER ARM LH
41. INSTALL FR WIPER ARM RH
42. INSTALL HOOD SUB-ASSY
43. INSPECT HOOD SUB-ASSY
44. ADJUST HOOD SUB-ASSY
45. INSTALL ENGINE UNDER COVER RH
46. INSTALL ENGINE UNDER COVER LH
47. INSTALL FRONT WHEELS
48. INSTALL SERVICE PLUG GRIP
49. CONNECT BATTERY NEGATIVE TERMINAL
50. ADD TRANSAXLE OIL
Fluid type: AUTO FLUID WS
Capacity: 3.8 liters (4.0 US qts, 3.3 Imp. qts)
51. INSPECT TRANSAXLE OIL
52. ADD COOLANT
53. CHECK FOR ENGINE COOLANT LEAKS
54. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
55. DELETE TORQUE ZERO POINT
56. PERFORM INITIALIZATION