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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 80 (Hybrid Transaxle System (P810) - Service Information) >> Hybrid Vehicle Transaxle >> Installation [11/2023 - ] >> Procedure

Installation [11/2023 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL OUTLET MOTOR HOSE 

    HINT: 

    Perform this procedure only when replacement of the outlet motor hose or motor cooling pipe assembly is necessary.

    1. Install the outlet motor hose to the motor cooling pipe assembly and slide the clip to secure it.
      GTY1179325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2 to 7 mm (0.0787 to 0.276 in.)
      *b Paint Mark (Front Side of Vehicle)
      *c 120° (Claw of Clip Location)
      *d Upper Side of Vehicle
      *e Front Side of Vehicle
      NOTE:
      • Make sure to slide the outlet motor hose until it contacts the hose stopper of the motor cooling pipe assembly.
      • Make sure that the paint mark of the outlet motor hose and claws of the clip are within the location shown in the illustration.
  2. INSTALL TUBE CONNECTOR 

    HINT: 

    Perform this procedure only when replacement of the tube connector or O-ring is necessary.

    1. Coat a new O-ring with Toyota Genuine ATF WS and install it to the tube connector.
    2. Using a 19 mm deep socket wrench, install the tube connector to the hybrid vehicle transaxle assembly.

      Torque: 15 N.m (153 kgf/cm, 11 ft.lbf) 

  3. INSTALL TRANSAXLE BREATHER PLUG 

    HINT: 

    Perform this procedure only when replacement of the transaxle breather plug is necessary.

    1. Install the transaxle breather plug to the hybrid vehicle transaxle assembly.

      Torque: 11.3 N.m (115 kgf/cm, 8 ft.lbf) 

  4. INSTALL STUD BOLT 
    1. Clean and degrease the 2 stud bolts and 2 stud bolt holes.
      GTY924035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply adhesive to 2 or 3 threads on the ends of the 2 stud bolts.
      GTY864031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      In order to ensure proper sealing of the 2 stud bolts, install them within 10 minutes of applying adhesive.

    3. Using a E10 "TORX" socket wrench, install the 2 stud bolts to the hybrid vehicle transaxle assembly.

      Torque: 30 N.m (306 kgf/cm, 22 ft.lbf) 

  5. INSTALL TRANSAXLE HOUSING PLUG 
    1. Install the transaxle housing plug and a new gasket to the hybrid vehicle transaxle assembly.

      Torque: 39.2 N.m (400 kgf/cm, 29 ft.lbf) 

  6. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the 4 wire harness clamp brackets to the hybrid vehicle transaxle assembly with the 4 bolts.
      GTY859993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt (A) 

      Torque: 20 N.m (204 kgf/cm, 15 ft.lbf) 

      Bolt (B) 

      Torque: 30 N.m (306 kgf/cm, 22 ft.lbf) 

  7. INSTALL TRANSMISSION WIRE 
    1. Install the transmission wire to the hybrid vehicle transaxle assembly with the bolt.

      Torque: 13 N.m (133 kgf/cm, 10 ft.lbf) 

    2. Connect the connector.
  8. INSTALL NO. 3 INVERTER BRACKET 
    1. Install the No. 3 inverter bracket to the hybrid vehicle transaxle assembly with the bolt.

      Torque: 55 N.m (561 kgf/cm, 41 ft.lbf) 

      GTY917441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 5 bolts.

      Torque: 55 N.m (561 kgf/cm, 41 ft.lbf) 

  9. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET 
    1. Install the No. 1 transmission control cable bracket to the hybrid vehicle transaxle assembly with the 2 bolts.

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

  10. INSTALL MOTOR COOLING PIPE ASSEMBLY 
    1. Temporarily install the motor cooling pipe assembly to the hybrid vehicle transaxle assembly with the oil cooler union bolt and a new gasket.
      GTY1178750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Cooler Union Bolt
      *2 Gasket
    2. Install the bolt.

      Torque: 19.5 N.m (199 kgf/cm, 14 ft.lbf) 

    3. Tighten the oil cooler union bolt.

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

  11. INSTALL MOTOR COOLING COOLER 
    1. Temporarily install the motor cooling cooler to the No. 1 transmission control cable bracket with the 3 bolts.
      GTY1179850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Tighten the 3 bolts in the order shown in the illustration.

      Torque: 11.5 N.m (117 kgf/cm, 8 ft.lbf) 

    3. Connect the No. 1 motor cooling hose to the tube connector, and slide the clip to secure it.
      GTY1179526Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 0 to 3 mm (0 to 0.118 in.)
      *b 2 to 7 mm (0.0787 to 0.276 in.)
      *c Paint Mark
      *d Marking
      *e Center of Paint Mark
      *f 45° (Claw of Clip Location)
      NOTE:
      • Make sure to slide the No. 1 motor cooling hose until it contacts the hose stopper of the tube connector.
      • Make sure to align the paint mark of the No. 1 motor cooling hose with the marking of the hybrid vehicle transaxle assembly.
      • Make sure that the claws of the clip are within the location shown in the illustration.
  12. CONNECT OUTLET MOTOR HOSE 

    See step  3

  13. INSTALL MOTOR CABLE 

    See step  1

  14. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY 
    1. Make sure that the knock pins are installed to the engine assembly.
      GTY876800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Knock Pin
    2. Align the knock pins with the holes in the hybrid vehicle transaxle assembly and, while keeping the contact surfaces of the engine assembly and hybrid vehicle transaxle assembly in close contact with one another, temporarily install the bolt.
      GTY917425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When tightening the bolts, be sure that the contact surfaces of the engine assembly and hybrid vehicle transaxle assembly are in close contact with one another.
      • Do not apply grease to the inner splines of the transmission input damper assembly or input shaft assembly.
      • Make sure that the wire harness or similar items are not pinched between the contact surfaces.
      • Do not use excessive force when installing the hybrid vehicle transaxle assembly.
      • Make sure to align the hybrid vehicle transaxle assembly so that the input shaft assembly of the hybrid vehicle transaxle assembly will be inserted straight into the inner splines of the transmission input damper assembly.
      • When inserting the input shaft assembly of the hybrid vehicle transaxle assembly into the inner splines of the transmission input damper assembly, do not shake the hybrid vehicle transaxle assembly excessively.
      • When installing the hybrid vehicle transaxle assembly to the engine assembly, make sure to securely fit the knock pins into the knock pin holes.
    3. While keeping the contact surfaces of the engine assembly and hybrid vehicle transaxle assembly in close contact with one another, install the 8 bolts.
      GTY931300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Bolt Length Torque
      (A) 50 mm (1.97 in.) 64 N.m (653 kgf/cm, 47 ft.lbf)
      (B), (C) 45 mm (1.77 in.) 46 N.m (469 kgf/cm, 34 ft.lbf)
      (D) 35 mm (1.38 in.) 25 N.m (255 kgf/cm, 18 ft.lbf)

      HINT: 

      • Bolt (A), (B), (D): Install from the hybrid vehicle transaxle assembly side.
      • Bolt (C): Install from the engine assembly side.
  15. INSTALL REAR ENGINE MOUNTING BRACKET 
    1. Install the rear engine mounting bracket to the hybrid vehicle transaxle assembly with the 4 bolts.
      GTY839912Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 42 N.m (428 kgf/cm, 31 ft.lbf) 

      HINT: 

      Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (A) → Fully tighten bolt (C)

  16. INSTALL REAR ENGINE MOUNTING INSULATOR 

    Refer to PROCEDURE - Step 11

  17. INSTALL FRONT ENGINE MOUNTING BRACKET 
    1. Install the front engine mounting bracket to the hybrid vehicle transaxle assembly with the 3 bolts.
      GTY843268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 42 N.m (428 kgf/cm, 31 ft.lbf) 

      HINT: 

      Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (C) → Fully tighten bolt (A)

  18. INSTALL FRONT ENGINE MOUNTING INSULATOR 

    Refer to PROCEDURE - Step 12

  19. INSTALL FRONT FRAME ASSEMBLY 

    Refer to PROCEDURE - Step 6

  20. INSTALL FLYWHEEL HOUSING SIDE COVER 
    1. Install the flywheel housing side cover to the engine assembly.
  21. INSTALL STARTER HOLE INSULATOR 
    1. Install the starter hole insulator to the engine assembly with the 2 bolts.

      Torque: 46 N.m (469 kgf/cm, 34 ft.lbf) 

  22. INSTALL TRANSAXLE UNDER STOPPER BRACKET 
    1. Install the transaxle under stopper bracket to the hybrid vehicle transaxle assembly with the 4 bolts.
      GTY943572Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 44 N.m (449 kgf/cm, 32 ft.lbf) 

      HINT: 

      Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (C) → Fully tighten bolt (A)

  23. CONNECT WATER HOSE 
    1. Engage the clamp to connect the water hose.
  24. CONNECT HV AIR CONDITIONING WIRE 
    1. Engage the guide to connect the HV air conditioning wire to the hybrid vehicle transaxle assembly.
    2. Connect the HV air conditioning wire to the hybrid vehicle transaxle assembly with the 2 bolts.

      Torque: 20 N.m (204 kgf/cm, 15 ft.lbf) 

  25. CONNECT ENGINE WIRE 
    1. Front side:
      1. Connect the engine wire with the 2 bolts.

        Torque: 20 N.m (204 kgf/cm, 15 ft.lbf) 

    2. Rear side:
      1. Engage the 6 clamps to connect the engine wire.
        GTY917462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Connect the engine wire with the 2 bolts.

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      3. Connect the wire harness connector to the rack and pinion power steering gear assembly.

        HINT: 

        Make sure that the connector is fully inserted before rotating the lock lever to engage the lock.

  26. INSTALL STEERING GEAR HEAT INSULATOR 

    Refer to PROCEDURE - Step 7

  27. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 

    Refer to INSTALLATION [11/2023 - ]

  28. PERFORM RESOLVER LEARNING 
    NOTE:

    If the hybrid vehicle transaxle assembly has been replaced, make sure to perform resolver learning.

    Refer to UTILITY [11/2023 - ]

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