Adjustment [09/2023 - ]: Procedure

1. The PC60 transaxle assembly with motor and inverter does not have an oil filler tube and oil level gauge. When adding hybrid transaxle fluid, add hybrid transaxle fluid through the refill plug hole on the automatic transaxle case sub-assembly. The hybrid transaxle fluid level can be adjusted by draining excess hybrid transaxle fluid (allowing excess hybrid transaxle fluid to overflow) through the No. 1 transmission oil filler tube of the transaxle housing.

   HINT: 

   "Overflow" indicates the condition under which hybrid transaxle fluid comes out of the overflow plug hole.

2. Before adjusting the hybrid transaxle fluid level, add the specified amount of hybrid transaxle fluid when the engine is cold and warm up the engine to circulate the hybrid transaxle fluid in the transaxle assembly with motor and inverter. Ensure that the hybrid transaxle fluid temperature is as specified and the engine is idling.
3. The PC60 transaxle assembly with motor and inverter requires Toyota Genuine ATF WS.

   Using hybrid transaxle fluid other than the above type may cause abnormal noise or vibration, or ultimately damage the transaxle of the vehicle.

4. When adjusting the hybrid transaxle fluid level, park the vehicle on level ground. Longitudinal tilt should be within +/-1°.
5. When performing the procedure, turn off all electrical devices, such as the air conditioning, headlights and electric fan motor, to reduce electrical load.
6. The hybrid transaxle fluid temperature in the text indicates the hybrid transaxle fluid temperature (in transmission valve body assembly) displayed on the GTS.
7. The adjustment should be performed according to the procedures and notes.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. The adjustment should be performed according to the procedure referenced in the work flow below.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Lift the vehicle.
   NOTE:

   Set the vehicle on a lift so that the vehicle is kept level when it is lifted up (make sure that the tilt angle from the front to rear and side to side of the vehicle is within +/- 1°).

2. Remove the No. 2 engine under cover assembly.

   Refer to PROCEDURE - Step 1

3. Remove the front fender apron seal LH.

   Refer to PROCEDURE - Step 11

1. Remove the refill plug and gasket from the automatic transaxle case sub-assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Using a 10 mm hexagon socket wrench, remove the overflow plug and gasket from the transaxle housing.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   • If hybrid transaxle fluid comes out after removing the overflow plug, wait until the hybrid transaxle fluid flow slows and only drips come out.
   • If hybrid transaxle fluid comes out, it is not necessary to perform the initial filling procedure. After checking the tightening torque of the No. 1 transmission oil filler tube, temporarily install the overflow plug.
3. Using a 6 mm hexagon socket wrench, check that the No. 1 transmission oil filler tube is tightened to the specified torque.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	No. 1 Transmission Oil Filler Tube

   Torque: 0.8 N.m (8 kgf/cm, 7 in.lbf) 

   NOTE:

   If the No. 1 transmission oil filler tube is not tightened to the specified torque, the amount of hybrid transaxle fluid cannot be precisely adjusted.

4. Perform initial filling.
   1. Fill the transaxle assembly with motor and inverter through the refill plug hole until hybrid transaxle fluid begins to come out of the overflow plug hole.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      NOTE:

      Use Toyota Genuine ATF WS.

      Using hybrid transaxle fluid other than the above type may cause abnormal noise or vibration, or ultimately damage the transaxle of the vehicle.

5. Wait until the hybrid transaxle fluid flow slows and only drips come out.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

6. Using a 10 mm hexagon socket wrench, temporarily install the gasket and overflow plug to the transaxle housing.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Reuse the old gasket as the overflow plug will be removed again to adjust the hybrid transaxle fluid level.

7. Temporarily install the gasket and refill plug to the automatic transaxle case sub-assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Reuse the old gasket as the refill plug will be removed again to adjust the hybrid transaxle fluid level.

1. Remove the refill plug and gasket from the automatic transaxle case sub-assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. Fill the transaxle assembly with motor and inverter with the correct amount of hybrid transaxle fluid as listed in the table below.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   Use Toyota Genuine ATF WS.

   Using hybrid transaxle fluid other than the above type may cause abnormal noise or vibration, or ultimately damage the transaxle of the vehicle.

   HINT: 

   The refill amount differs depending on the operation that was performed.

   Reference Capacity

   Performed Repair	Fill Amount
   Transaxle assembly with motor and inverter replacement	4.7 liters (5.0 US qts, 4.1 Imp. qts)
   Removal and installation of the automatic transmission case cover	4.3 liters (4.5 US qts, 3.8 Imp. qts)
   Removal and installation of the front drive shaft assembly	4.3 liters (4.5 US qts, 3.8 Imp. qts)
   Removal and installation of the transmission valve body assembly	4.3 liters (4.5 US qts, 3.8 Imp. qts)
   Repair of an hybrid transaxle fluid leak due to a loose case plug, or a faulty plug gasket or O-ring	0.5 liters (0.5 US qts, 0.4 Imp. qts)

3. Temporarily install the gasket and refill plug to avoid hybrid transaxle fluid spillage.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   HINT: 

   Reuse the old gasket as the refill plug will be removed again to adjust the hybrid transaxle fluid level.

4. Lower the vehicle.

HINT: 

The actual hybrid transaxle fluid temperature can be checked on the Data List using the GTS.

1. Connect the GTS to the DLC3 with the ignition switch off.
2. Turn the ignition switch to ON and turn the GTS on.
3. In order to check the hybrid transaxle fluid temperature, with the Data List "A/T Oil Temperature No. 1" displayed, perform the Active Test "Activate the TC Terminal".

   Powertrain > Transmission > Active Test 

   Active Test Display
   Activate the TC Terminal

   Data List Display
   A/T Oil Temperature No. 1

4. Depress and hold the brake pedal.
5. Turn the ignition switch to ON (READY).
   NOTE:

   To reduce load, make sure that all electrical systems, such as the air conditioning, lighting system, electric fan and audio system are off.

6. Slowly move the shift lever from P to D, then back to P.

   HINT: 

   Keep the shift lever in each position for approximately 3 seconds.

7. While observing the D shift indicator on the combination meter, move the shift lever back and forth between N and D at an interval of less than 1.5 seconds for 6 seconds or more.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Shift Position
   *b	Indication of Shift Position
   *c	Hybrid Transaxle Fluid Temperature Detection Mode
   *d	6 sec. or more
   *e	2 sec.
   *f	Less than 1.5 sec.

   NOTE:

   Do not pause for more than 1.5 seconds.

   HINT: 

   Performing this operation will cause the vehicle to enter hybrid transaxle fluid temperature detection mode.

8. Check that the D shift indicator comes on for 2 seconds.

   HINT: 

   • When hybrid transaxle fluid temperature detection mode is activated, the D shift indicator on the combination meter comes on for 2 seconds.
   • If the D shift indicator does not come on for 2 seconds, return to the first step (perform the Active Test Activate the TC Terminal and set it to "ON") and perform the procedure again.
9. Move the shift lever to P.
10. Release the brake pedal.
11. According to the display on the GTS, perform the Active Test Activate the TC Terminal and set it to "OFF".
    NOTE:

    Make sure that the Active Test is changed to "OFF". If it is not, the hybrid transaxle fluid level cannot be precisely adjusted due to fluctuations in engine speed.

    HINT: 

    • Changing the Active Test to "OFF" activates engine idle speed control mode.
    • In engine idle speed control mode, engine idle speed control starts when the hybrid transaxle fluid temperature reaches the specified temperature and the engine speed is maintained.
    • Even after the Active Test is changed to "OFF", hybrid transaxle fluid temperature detection mode will be active until the ignition switch is turned off.
12. With the shift lever in P and the engine speed at 1500 rpm or more continuously for 5 seconds or more, switch the water control valve to injection control to stabilize the hybrid transaxle fluid temperature.

    HINT: 

    Since the engine speed does not rise while the HV battery is charging, wait until charging is complete.

13. Adjust the hybrid transaxle fluid temperature to the hybrid transaxle fluid level adjustment temperature.
    HYBRID TRANSAXLE FLUID TEMPERATURE
    
    

    Below Hybrid Transaxle Fluid Level Adjustment Temperature	Hybrid Transaxle Fluid Level Adjustment Temperature	Above Hybrid Transaxle Fluid Level Adjustment Temperature
    35°C or less (95°F or less)	35 to 45°C (95 to 113°F)	45°C or more (113°F or more)

    NOTE:

    • If the hybrid transaxle fluid temperature is within the hybrid transaxle fluid level adjustment temperature range, immediately proceed to the "Adjust Hybrid Transaxle Fluid Level" procedure.
    • If the hybrid transaxle fluid temperature is 45°C (113°F) or more, stop the engine and wait until the hybrid transaxle fluid temperature drops to 45°C (113°F) or less. Then perform the "Adjust Hybrid Transaxle Fluid Temperature" procedure again from the beginning.

    HINT: 

    • In hybrid transaxle fluid temperature detection mode, the D shift indicator comes on, turns off or blinks depending on the hybrid transaxle fluid temperature.
    • The hybrid transaxle fluid adding procedure should be performed when the D shift indicator is on (the hybrid transaxle fluid temperature is between 35 °C (95 °F) and 45 °C (113 °F)).
    D SHIFT INDICATOR
    
    

    Below Hybrid Transaxle Fluid Level Adjustment Temperature (35°C or less) (95°F or less)	Hybrid Transaxle Fluid Level Adjustment Temperature (35 to 45°C) (95 to 113°F)	Above Hybrid Transaxle Fluid Level Adjustment Temperature (45°C or more) (113°F or more)
    OFF	ON	Blinks

1. Turn the ignition switch off.
2. Depress and hold the brake pedal.
3. Turn the ignition switch to ON (READY). [#1]
   NOTE:

   To reduce load, make sure that all electrical systems, such as the air conditioning, lighting system, electric fan and audio system are off.

4. Slowly move the shift lever from P to D, then back to P. [#2]

   HINT: 

   Keep the shift lever in each position for approximately 3 seconds.

5. While observing the D shift indicator on the combination meter, move the shift lever back and forth between N and D at an interval of less than 1.5 seconds for 12 seconds or more. [#3]

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Shift Position
   *b	Indication of Shift Position
   *c	Hybrid Transaxle Fluid Temperature Detection Mode
   *d	12 sec. or more
   *e	2 sec.
   *f	Less than 1.5 sec.

   NOTE:

   Do not pause for more than 1.5 seconds.

   HINT: 

   • Performing this operation will cause the vehicle to enter hybrid transaxle fluid temperature detection mode and engine idle speed control mode.
   • In engine idle speed control mode, engine idle speed control starts when the hybrid transaxle fluid temperature reaches the specified temperature and the engine speed is maintained.
   • Perform [#1] to [#3] within 60 seconds.
6. Check that the D shift indicator comes on for 2 seconds.

   HINT: 

   • When hybrid transaxle fluid temperature detection mode is activated, the D shift indicator on the combination meter comes on for 2 seconds.
   • If the D shift indicator does not come on for 2 seconds, return to the first step (Start the engine. [#1]) and perform the procedure again.
   • Hybrid transaxle fluid temperature detection mode is active until the ignition switch is turned off.
7. Move the shift lever to P.
8. Release the brake pedal.
9. With the shift lever in P and the engine speed at 1500 rpm or more continuously for 5 seconds or more, switch the water control valve to injection control to stabilize the hybrid transaxle fluid temperature.

   HINT: 

   Since the engine speed does not rise while the HV battery is charging, wait until charging is complete.

10. Allow the engine to idle until the D shift indicator comes on again.
    D SHIFT INDICATOR
    
    

    Below Hybrid Transaxle Fluid Level Adjustment Temperature (35°C or less) (95°F or less)	Hybrid Transaxle Fluid Level Adjustment Temperature (35 to 45°C) (95 to 113°F)	Above Hybrid Transaxle Fluid Level Adjustment Temperature (45°C or more) (113°F or more)
    OFF	ON	Blinks

    NOTE:

    • If the D shift indicator is on, immediately proceed to the "Adjust Hybrid Transaxle Fluid Level" procedure.
    • If the D shift indicator blinks, stop the engine and wait until the hybrid transaxle fluid temperature drops to 35°C (95°F) or less (the indicator turns off). Then perform the "Adjust Hybrid Transaxle Fluid Temperature" procedure again from the beginning.

    HINT: 

    • In hybrid transaxle fluid temperature detection mode, the D shift indicator comes on, turns off, or blinks depending on the hybrid transaxle fluid temperature.
    • The hybrid transaxle fluid filling procedure should be performed when the D shift indicator is on (the hybrid transaxle fluid temperature is within the hybrid transaxle fluid level adjustment temperature range).

1. Lift the vehicle.
   NOTE:

   Set the vehicle on a lift so that the vehicle is kept level when it is lifted up (make sure the tilt angle from the front to rear and side to side of the vehicle is within +/- 1°).

2. Using a 10 mm hexagon socket wrench, remove the overflow plug and gasket from the transaxle housing.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   WARNING:

   Be careful as the hybrid transaxle fluid coming out of the overflow plug hole is hot.

3. Check the amount of hybrid transaxle fluid that comes out of the overflow plug hole.
   NOTE:

   If only a small amount of hybrid transaxle fluid (approximately 2 cc) comes out of the overflow plug hole, then only hybrid transaxle fluid remaining in the No. 1 transmission oil filler tube has come out. This condition is not considered as overflow, so it is necessary to add hybrid transaxle fluid.

   • If the amount of hybrid transaxle fluid that comes out of the overflow plug hole is large, proceed to step [#1].
   • If no hybrid transaxle fluid comes out of the overflow plug hole, proceed to step [#2].
4. If the amount of hybrid transaxle fluid that comes out of the overflow plug hole is large. [#1]
   1. Wait until the hybrid transaxle fluid flow slows and only drips come out.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The hybrid transaxle fluid flow will not stop completely because the hybrid transaxle fluid continues to expand as its temperature increases.

5. If no hybrid transaxle fluid comes out of the overflow plug hole. [#2]
   1. If no hybrid transaxle fluid comes out, remove the refill plug and gasket from the automatic transaxle case sub-assembly. Pour hybrid transaxle fluid into the refill plug hole until hybrid transaxle fluid comes out of the overflow plug hole.
      NOTE:

      Use Toyota Genuine ATF WS.

      Using hybrid transaxle fluid other than the above type may cause abnormal noise or vibration, or ultimately damage the transaxle of the vehicle.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   2. Wait until the hybrid transaxle fluid flow slows and only drips come out.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The hybrid transaxle fluid flow will not stop completely because the hybrid transaxle fluid continues to expand as its temperature increases.

6. Using a 10 mm hexagon socket wrench, install the overflow plug and a new gasket to the transaxle housing.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 50 N.m (510 kgf/cm, 37 ft.lbf) 

   NOTE:

   To prevent the gasket from being deformed when tightening, coat it with Toyota Genuine ATF WS.

7. Install the refill plug and a new gasket to the automatic transaxle case sub-assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 47 N.m (479 kgf/cm, 35 ft.lbf) 

   NOTE:

   To prevent the gasket from being deformed when tightening, coat it with Toyota Genuine ATF WS.

8. Lower the vehicle.
9. Turn the ignition switch off.

1. Lift the vehicle.
2. Clean each part.
3. Check for hybrid transaxle fluid leaks.
4. Install the front fender apron seal LH.

   Refer to PROCEDURE - Step 79

5. Install the No. 2 engine under cover assembly.

   Refer to PROCEDURE - Step 6

6. Lower the vehicle.
7. Operation complete.