Installation

HYBRID TRANSMISSION / TRANSAXLE: HYBRID VEHICLE TRANSAXLE:

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





(a) Install the clamp in the position shown in the illustration with the 6 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)





(b) Install the No. 3 engine mounting bracket with the 3 bolts.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
2. INSTALL NO. 6 INVERTER COOLING HOSE





(a) Connect the inverter cooling hose and install the clamp.
3. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY





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

- 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.





(b) Install the housing side cover and starter cover with the 2 bolts.
Torque: 32 Nm (326 kgf-cm, 23 ft-lbf)
4. INSTALL NO. 3 ENGINE MOUNTING BRACKET





(a) Install the engine mounting bracket to the engine mounting insulator with the nut.
Torque: 80 Nm (816 kgf-cm, 59 ft-lbf)
5. REMOVE NO. 1 ENGINE HANGER
(a) Remove the bolt and engine hanger.
6. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (Installation)

7. CONNECT EXHAUST PIPE ASSEMBLY
(a) Connect the exhaust pipe (Installation).
8. INSTALL FRONT DRIVE SHAFT ASSEMBLY
(a) Install the front drive shaft (Installation).
9. CONNECT NO. 4 INVERTER COOLING HOSE





(a) Connect the 3 hoses with the 4 clamps.
10. CONNECT CONNECTOR





(a) Connect the ground wire with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)





(b) Connect the 2 clamps.





(c) Install the transmission case cover to the hybrid vehicle transaxle with the 3 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
(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.
11. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner (Installation).
12. INSTALL INVERTER WITH CONVERTER ASSEMBLY
(a) Install with inverter converter (Installation).
13. INSTALL COWL TOP FRONT PANEL SUB-ASSEMBLY OUTER
(a) Install the cowl top front panel.
14. INSTALL FRONT WIPER ARM RH
(a) Install the front wiper arm.
15. INSTALL FRONT WIPER ARM LH
(a) Install the front wiper arm.
16. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood.
17. ADJUST HOOD SUB-ASSEMBLY
(a) Adjust the hood.
18. INSTALL ENGINE UNDER COVER RH
19. INSTALL ENGINE UNDER COVER LH
20. INSTALL FRONT WHEEL
21. INSTALL SERVICE PLUG GRIP
(a) Install the service plug grip (Installation).
22. 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).

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
(a) Inspect the transaxle oil (Hybrid Transaxle System).
25. ADD COOLANT (for Inverter)
(a) Add the coolant (Coolant).
26. INSPECT FOR COOLANT LEAK (for Inverter)
(a) Check for engine coolant leakage (Testing and Inspection).
27. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment.
28. PERFORM CALIBRATION
(a) Perform calibration.