Installation [10/2018 - ]: Procedure

HINT: 

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

1. Coat a new O-ring with ATF.
2. Install the union and O-ring to the hybrid vehicle transaxle assembly.

   Torque: 27 N.m (275 kgf/cm, 20 ft.lbf) 

1. Clean and degrease the 2 stud bolt holes of the hybrid vehicle transaxle assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Apply adhesive to 2 or 3 threads on the ends of the 2 stud bolts.

   Courtesy 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 E8 "TORX" socket wrench, install the 2 stud bolts to the hybrid vehicle transaxle assembly.

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

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) 

1. Install the 2 wire harness clamp brackets to the hybrid vehicle transaxle assembly with the 2 bolts.

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

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) 

1. Temporarily install the hose bracket to the hybrid vehicle transaxle assembly with the 2 bolts.
   Fig 1: Hose Bracket Bolt Installation Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tighten the 2 bolts in the order shown in the illustration.

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

1. Install the No. 1 water hose clamp bracket to the hybrid vehicle transaxle assembly with the bolt.

   Torque: 19 N.m (194 kgf/cm, 14 ft.lbf) 

1. Temporarily install the No. 1 motor cooling pipe to the union with the flare nut.
2. Install the No. 1 oil cooler tube clamp to the No. 1 transmission control cable bracket with the bolt.

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

3. Using a 17 mm union nut wrench, tighten the flare nut to install the No. 1 motor cooling pipe.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Torque Wrench Fulcrum Length

   Specified Tightening Torque 

   Torque: 34.3 N.m (350 kgf/cm, 25 ft.lbf) 

   HINT: 

   • calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

     Refer to PRECAUTION [10/2018 - 07/2022] , or refer to PRECAUTION [07/2022 - ]

   • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)):

     29.4 N.m (300 kgf/cm, 22 ft.lbf)

1. Temporarily install the motor cooling cooler with No. 2 motor cooling pipe to the hybrid vehicle transaxle assembly with the 3 bolts.
   Fig 2: Motor Cooling Cooler With No. 2 Motor Cooling Pipe Bolt Installation Sequence

   Courtesy 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. Temporarily install the No. 2 motor cooling pipe to the hybrid vehicle transaxle assembly with the oil cooler union bolt and a new gasket.
4. Install the No. 1 oil cooler tube clamp to the hose bracket with the bolt.

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

5. Tighten the oil cooler union bolt to install the No. 2 motor cooling pipe.

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

6. Connect the No. 1 motor cooling hose to the No. 1 motor cooling pipe and slide the clip to secure it.
   NOTE:

   Make sure to align the paint mark on the No. 1 motor cooling pipe with the paint mark on the No. 1 motor cooling hose.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	2 to 7 mm (0.0787 to 0.276 in.)
   *b	Paint Mark

See step  1

1. Install the No. 2 engine moving control rod to the hybrid vehicle transaxle assembly with the 5 bolts in the order shown in the illustration.

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

   Fig 3: No. 2 Engine Moving Control Rod Bolt Installation Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Temporarily Tighten

1. Temporarily install the front suspension crossmember sub-assembly to the No. 2 engine moving control rod with the bolt.

1. Make sure that the knock pins are installed to the engine assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   Knock Pin

2. Align the knock pins with the holes in the hybrid 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 (A).

   Courtesy 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 engine 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 engine assembly.
   • When installing the engine assembly to the hybrid vehicle transaxle 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Bolt	Bolt Length	Torque
   (A), (B)	50 mm (1.97 in.)	64 N.m (653 kgf/cm, 47 ft.lbf)
   (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)

1. Install the flywheel housing side cover to the engine assembly.

1. Install the starter hole insulator to the engine assembly with the 2 bolts.

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

1. Connect the connector and slide the green-colored lock as shown in the illustration to lock it securely.
   WARNING:

   Make sure to wear insulated gloves.

   NOTE:

   Make sure that the connector is connected securely.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Green-colored Lock
   	Slide

2. Engage the clamp.
3. Engage the guide to install the HV air conditioning wire to the hybrid vehicle transaxle assembly.
4. Install the bolt.

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

1. Connect the generator temperature sensor connector.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Resolver (Transmission Fluid Temperature Sensor) Connector
   *2	Shift Lever Position Sensor Connector
   *3	Generator Temperature Sensor Connector

2. Confirm that no foreign matter or water has entered the connector of the shift lever position sensor and connect the connector.
3. Connect the resolver (transmission fluid temperature sensor) connector.
4. Install the bolt.

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

5. Engage the clamp.
6. Engage the 5 clamps.

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

Refer to PROCEDURE - Step 13 [10/2018 - 07/2022] , or refer to PROCEDURE - Step 13 [07/2022 - ]

Refer to PROCEDURE - Step 29 [10/2018 - 07/2022] , or refer to PROCEDURE - Step 29 [07/2022 - ]

Refer to INSTALLATION [10/2018 - 07/2022] , or refer to INSTALLATION [07/2022 - ]