Installation [03/2024 - ]: Procedure

HINT: 

Perform this procedure only when replacement of the outlet motor hose or No. 2 motor cooling pipe is necessary.

1. Courtesy 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	-	-

   1. Install the outlet motor hose to the No. 2 motor cooling pipe and slide the clip to secure it.
      NOTE:

      • Make sure to slide the outlet motor hose until it contacts the hose stopper of the No. 2 motor cooling pipe.
      • Make sure that the paint mark of the outlet motor hose and claws of the clip are within the location shown in the illustration.

HINT: 

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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

HINT: 

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

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Apply adhesive to the 2 stud bolts.

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

   2. Using an 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) 

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

1. Courtesy 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) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Install the No. 3 inverter bracket to the hybrid vehicle transaxle assembly with the bolt as shown in the illustration.

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

   2. Install the 5 bolts.

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   Oil Cooler Union Bolt

   *2

   Gasket

   1. Temporarily install the motor cooling pipe assembly to the hybrid vehicle transaxle assembly with the oil cooler union bolt and a new 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) 

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Temporarily Tighten

   -

   -

   1. Install the No. 2 transmission oil cooler bracket to the hybrid vehicle transaxle assembly with the 2 bolts in the order shown in the illustration.

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

1. Fig 1: Motor Cooling Cooler Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Temporarily Tighten

   -

   -

   1. Install the motor cooling cooler to the No. 2 transmission oil cooler bracket with the 3 bolts in the order shown in the illustration.

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

2. Courtesy 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)

   1. Connect the No. 1 motor cooling hose to the transaxle housing tube connector, and slide the clip to secure it.
      NOTE:

      • Make sure to slide the No. 1 motor cooling hose until it contacts the hose stopper of the transaxle housing 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.

See step  3

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1

   Knock Pin

   -

   -

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

      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.

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Install the rear engine mounting bracket to the hybrid vehicle transaxle assembly with the 4 bolts.

      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)

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Install the front engine mounting bracket to the hybrid vehicle transaxle assembly with the 3 bolts.

      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)

Refer to PROCEDURE - Step 13

Refer to PROCEDURE - Step 9

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Install the transaxle under stopper bracket to the hybrid vehicle transaxle assembly with the 4 bolts.

      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)

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

1. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

2. Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   1. Engage the 6 clamps to connect the engine wire.
   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.

Refer to INSTALLATION [03/2024 - ]