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Home >> Toyota >> 2016 >> Prius C One >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Hybrid Transaxle (P510) (Service Information) >> Hybrid Vehicle Transaxle >> Installation [11/2015 - 06/2017] >> Procedure

Installation [11/2015 - 06/2017]: Procedure

  1. INSTALL TRANSAXLE HSG AND CASE WITH HEAD STRAIGHT SCREW PLUG 
    1. Install a new gasket and the transaxle HSG and case with head straight screw plug to the hybrid vehicle transaxle assembly.

      Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 

  2. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the hybrid vehicle transaxle assembly with the bolt.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

  3. INSTALL TRANSMISSION CONTROL CABLE SUPPORT 
    1. Install the 2 transmission control cable supports to the hybrid vehicle transaxle assembly with the 3 bolts.

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

  4. INSTALL MOTOR CABLE BRACKET 
    1. Install the motor cable bracket to the transmission control cable support with the bolt.

      Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf) 

  5. INSTALL AUTOMATIC TRANSMISSION CASE COVER 

    HINT: 

    Perform this procedure only when replacement of the automatic transmission case cover is necessary.

    1. Install the automatic transmission case cover to the hybrid vehicle transaxle assembly with the 2 bolts.

      Torque: 13 N*m (132 kgf*cm, 10 ft.*lbf) 

  6. INSTALL SHIFT LEVER POSITION SENSOR 

    HINT: 

    Perform this procedure only when replacement of the automatic transmission case cover is necessary.

    1. Install the shift lever position sensor to the manual valve shaft.
      NOTE:
      • Do not reuse the shift lever position sensor if it has been dropped or subjected to a severe impact.
      • Do not allow moisture to adhere to the connector terminal.
    2. Temporarily install the 2 bolts.
    3. Install the lock plate and tighten the nut.

      Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 

    4. Temporarily install the transmission control shaft lever to the manual valve shaft.
    5. Turn the lever clockwise until it stops, then turn it counterclockwise 2 notches.
      GTY722644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
    6. Remove the transmission control shaft lever from the manual valve shaft.
    7. Align the protruding part with the neutral basic line.
      GTY732471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      TEXT IN ILLUSTRATION

      *a Neutral Basic Line
      *b Protruding
      *c Range of Play
      NOTE:

      There is play on the nut stopper side (protruding part). Align the center point of the range of the play with the neutral basic line.

    8. Tighten the 2 bolts in the order shown in the illustration.
      Fig 1: Lock Plate Tightening Sequence
      GTY686565Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.

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

    9. Using a screwdriver, bend down the tabs of the lock plate.
  7. INSTALL TRANSMISSION CONTROL SHAFT LEVER 
    1. Install the transmission control shaft lever, washer and nut to the manual valve shaft.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

  8. 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) 

  9. INSTALL MOTOR CABLE 

    See step  1

  10. INSTALL MOTOR COOLING PIPE ASSEMBLY 
    1. Install a new O-ring and union to the hybrid vehicle transaxle assembly.

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

    2. Temporarily install the motor cooling pipe assembly to the hybrid vehicle transaxle assembly with a new gasket and union bolt.
      GTY719766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      TEXT IN ILLUSTRATION

      *1 Gasket
      *2 Union Bolt
      *3 Transaxle Case
      *a Stopper
      *b 17 mm Union Nut Wrench
      *c Torque Wrench Fulcrum Length
    3. Install the oil cooler tube clamp and motor cooling pipe assembly to the No. 1 transmission control cable bracket with the bolt.

      Torque: 12 N*m (117 kgf*cm, 8 ft.*lbf) 

    4. Tighten the union bolt with the motor cooling pipe assembly stopper pressed against the transaxle case.

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

    5. Using a 17 mm union nut wrench, connect the motor cooling pipe assembly to the union.

      Specified Tightening Torque 

      Torque: 34 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 [11/2015 - 06/2017] ).
      • 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 N*m (296 kgf*cm, 21 ft.*lbf)
      • Turn the flare nut while holding the union.
  11. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY 
    1. Make sure that the 2 knock pins are installed to the engine.
      GTY739935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      TEXT IN ILLUSTRATION

      *1 Knock Pin
    2. Temporarily install the hybrid vehicle transaxle assembly to the engine with the 2 bolts.

      HINT: 

      Temporarily install bolt (B) first.

    3. Fully tighten the 2 bolts in the order of (A) and (B).

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

      NOTE:
      • Make sure that the wire harness or similar items are not pinched between the contact surfaces.
      • Do not forcibly pry on the hybrid vehicle transaxle assembly.
      • Make sure to align the hybrid vehicle transaxle assembly so that the input shaft of the hybrid vehicle transaxle assembly will be inserted straight into the inner splines of the transmission input damper assembly.
      • Do not apply grease either to the spline or to the input shaft.
      • When inserting the input shaft 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 mounting the hybrid vehicle transaxle assembly to the engine, make sure to securely fit the knock pins into the knock holes.
      • When tightening the bolts, be sure that the mating surfaces of the engine and the hybrid vehicle transaxle assembly are in close contact with one another.

      Bolt Length

      45 mm (1.77 in.)

    4. Install the 4 bolts.
      GTY734803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.

      Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) 

      Bolt Length

      45 mm (1.77 in.)

    5. Engage the claw and install the flywheel housing side cover to the engine.
    6. Install the starter hole heat insulator to the engine with the 2 bolts.

      Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) 

      Bolt Length

      45 mm (1.77 in.)

    7. Install the drive shaft heat insulator bracket to the engine with the 2 bolts.

      Torque: 30 N*m (301 kgf*cm, 22 ft.*lbf) 

      Bolt Length

      45 mm (1.77 in.)

    8. Connect the clamp to the drive shaft heat insulator bracket.
    9. Install the drive shaft heat insulator sub-assembly to the engine and drive shaft heat insulator bracket with the bolt and nut.

      Torque: 18 N*m (179 kgf*cm, 13 ft.*lbf) 

    10. Install the 2 wire harness clamp brackets and transmission control cable clamp to the hybrid vehicle transaxle assembly with the 3 bolts.
      GTY702029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      TEXT IN ILLUSTRATION

      *1 Wire Harness Clamp Bracket
      *2 Transmission Control Cable Clamp

      Bolt (A) 

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

      Bolt (B) 

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

  12. INSTALL ENGINE MOUNTING BRACKET LH 
    1. Clean and degrease the bolts and bolt holes.
    2. Apply adhesive to 2 or 3 threads on the ends of the 4 bolts.
      GTY734242Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
      TEXT IN ILLUSTRATION

      *1 Adhesive
      NOTE:

      In order to ensure proper installation of the 4 bolts, apply adhesive to the 4 bolts and install them within 10 minutes of adhesive application.

    3. Temporarily install the engine mounting bracket LH to the hybrid vehicle transaxle assembly with the 4 bolts.
      GTY702865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.

      HINT: 

      Temporarily install bolt (D) first.

    4. Fully tighten the 4 bolts in the order of (A), (B), (C) and (D).

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

    5. Install the engine mounting insulator LH to the engine mounting bracket LH with the through bolt and nut.

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

      NOTE:

      Turn the through bolt while holding the nut.

  13. INSTALL ENGINE LATERAL CONTROL ROD 
    1. Temporarily install the engine lateral control rod to the hybrid vehicle transaxle assembly with the bolt.
      GTY327679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.
    2. Tighten the 4 bolts in the order shown in the illustration.
      Fig 2: Engine Lateral Control Rod Tightening Sequence
      GTY686681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002.

      Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf) 

  14. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  15. REMOVE NO. 1 ENGINE HANGER 

    Refer to PROCEDURE - Step 49

  16. INSTALL EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  17. INSTALL NO. 2 EGR PIPE 

    Refer to PROCEDURE - Step 2

  18. INSTALL FRONT DRIVE SHAFT ASSEMBLY 

    (Refer to INSTALLATION [11/2015 - ] )

  19. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  20. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  21. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  22. INSTALL COLUMN HOLE COVER SILENCER SHEET 

    Refer to PROCEDURE - Step 8

  23. CONNECT WIRE HARNESS 
    1. Connect the 7 clamps, 4 connectors and wire harness to the hybrid vehicle transaxle assembly with the 3 bolts.

      Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

    2. Connect the 4 clamps and No. 2 engine wire.
  24. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Connect the transmission control cable assembly to the transmission control cable clamp and transmission control cable support.
    2. Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.
    3. Install the transmission control cable assembly to the transmission control shaft lever with the nut.

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

  25. INSTALL INVERTER BRACKET ASSEMBLY 

    Refer to PROCEDURE - Step 27

  26. INSTALL INVERTER WITH CONVERTER ASSEMBLY 

    (Refer to INSTALLATION [11/2015 - ] )

  27. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 16

  28. INSTALL FRONT NO. 1 VENTILATOR SEAL 

    Refer to PROCEDURE - Step 17

  29. INSTALL FRONT AIR SHUTTER SEAL 

    Refer to PROCEDURE - Step 18

  30. INSTALL INNER COWL TOP TO COWL BRACE 

    Refer to PROCEDURE - Step 19

  31. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    (Refer to INSTALLATION [11/2015 - ] )

  32. INSTALL HOOD SUB-ASSEMBLY 
    1. Install the hood sub-assembly to the hood hinge assembly LH and hood hinge assembly RH with the 4 bolts.

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

  33. INSPECT HOOD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  34. ADJUST HOOD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  35. INSTALL SERVICE PLUG GRIP 

    (Refer to INSTALLATION [11/2015 - 06/2017] )

  36. ADD COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  37. ADD COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 2

  38. ADD HYBRID TRANSAXLE FLUID 

    See step  2

  39. INSPECT HYBRID TRANSAXLE FLUID 

    See step  1

  40. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1

  41. INSPECT FOR COOLANT LEAK (for Inverter) 

    Refer to PROCEDURE - Step 1

  42. INSPECT FOR HYBRID TRANSAXLE FLUID LEAK 
  43. INSPECT FOR EXHAUST GAS LEAK 
  44. INSTALL FRONT WHEELS 

    Refer to PROCEDURE - Step 10

  45. INSPECT SHIFT LEVER POSITION SENSOR POSITION 

    See step  1

  46. ADJUST SHIFT LEVER POSITION SENSOR POSITION 

    See step  2

  47. INSPECT SHIFT LEVER POSITION 

    See step  1

  48. ADJUST SHIFT LEVER POSITION 

    See step  2

  49. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY 

    Refer to PROCEDURE - Step 59

  50. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    (Refer to ADJUSTMENT [11/2015 - 06/2017] )

  51. CHECK ABS SPEED SENSOR SIGNAL 

    (Refer to TEST MODE PROCEDURE [11/2015 - ] )

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