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Home >> Toyota >> 2018 >> Highlander XLE, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 139 (Hybrid Transaxle (P313) (Service Information)) >> Hybrid Vehicle Transaxle >> Installation [11/2016 - ] >> Procedure

Installation [11/2016 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL HYBRID TRANSAXLE MASS DAMPER 
    1. Install the hybrid transaxle mass damper and a new gasket to the hybrid vehicle transaxle assembly.

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

  2. SUPPORT ENGINE ASSEMBLY 
    1. Set an engine lifter.
      GTY718255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that there is clearance between the engine oil pan assembly and engine lifter.

  3. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY 
    1. Clean and degrease the bolt hole.
      GTY714107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Make sure that the 2 knock pins are installed to the engine assembly.
      GTY739506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Knock Pin
    3. Temporarily install the bolt.
      NOTE:
      • 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 engaging the input shaft assembly of the hybrid vehicle transaxle assembly to 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.
      • When tightening the bolt, be sure that the contact surfaces of the engine assembly and the hybrid vehicle transaxle assembly are in close contact with one another.
      • Do not apply grease either to the inner splines or to the input shaft assembly.
      • 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.
    4. Install the 5 bolts in the order shown in the illustration.
      Fig 1: Tightening Sequence Of Hybrid Vehicle Transaxle Assembly
      GTY730362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (A)
      Bolt (B)

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

      HINT: 

      Bolt Length 

      • for Bolt (A) : 55 mm (2.17 in.)
      • for Bolt (B) : 65 mm (2.56 in.)
    5. Install the 4 bolts.
      GTY693046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      for Bolt (A) 

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

      for Bolt (B) 

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      HINT: 

      Bolt Length 

      • for Bolt (A) : 55 mm (2.17 in.)
      • for Bolt (B) : 33 mm (1.30 in.)
    6. Install a new bolt.
      GTY714107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      Bolt Length 

      41 mm (1.61 in.)

  4. INSTALL BELT 
    1. Install SST to the vehicle body as shown in the illustration.
      GTY714424Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09727-00110 
    2. Using the ratchet buckle, tighten the 2 belts until there is no slack.
      GTY737811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Ratchet Buckle - -
  5. INSTALL MANIFOLD STAY 
    1. Install the bolt and nut in the order shown in the illustration.
      GTY696663Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Bolt 

      Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 

      Nut 

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

  6. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover with the 2 bolts.

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

  7. INSTALL FRONT ENGINE MOUNTING BRACKET 
    1. Install the front engine mounting bracket to the hybrid vehicle transaxle assembly with the 3 bolts.

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

  8. INSTALL NO. 3 AUTOMATIC TRANSMISSION CASE COVER 
    1. Install the No. 3 automatic transmission case cover to the hybrid vehicle transaxle assembly with the 2 bolts and a new clip.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*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 OUTLET OIL COOLER TUBE SUB-ASSEMBLY 
    1. Install the No. 1 oil cooler tube clamp with the bolt as shown in the illustration.
      GTY602100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Claw

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

    2. Install the oil cooler tube union and a new gasket to the hybrid vehicle transaxle assembly.

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

    3. Temporarily install a new outlet oil cooler tube sub-assembly to the oil cooler tube union.
    4. Install the No. 2 oil cooler tube clamp to the No. 1 oil cooler tube clamp with the bolt.

      Torque: 8.2 N*m (84 kgf*cm, 73 in.*lbf) 

      NOTE:

      Check that the outlet oil cooler tube sub-assembly is securely installed to the No. 2 oil cooler tube clamp.

    5. Using a 17 mm union nut wrench, install the outlet oil cooler tube sub-assembly to the oil cooler tube union.

      Specified tightening torque 

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

      NOTE:
      • Turn the outlet oil cooler tube sub-assembly while holding the oil cooler tube union.
      • Make sure the outlet oil cooler tube sub-assembly is aligned with the oil cooler tube union to prevent the threads of the outlet oil cooler tube sub-assembly from being damaged.

      HINT: 

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

        Refer to PRECAUTION [11/2016 - ]

      • 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)

  11. INSTALL NO. 3 TRANSMISSION CONTROL CABLE BRACKET 
    1. Install the No. 3 transmission control cable bracket to the hybrid vehicle transaxle assembly with the bolt.

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

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

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

  13. INSTALL MOTOR CABLE BRACKET 
    1. Install the motor cable bracket to the hybrid vehicle transaxle assembly with the bolt.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

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

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

  15. INSTALL ENGINE MOUNTING INSULATOR LH 
    1. Install the engine mounting insulator LH with the nut.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

    2. Install the HV transaxle mass damper with the bolt.

      Torque: 13.5 N*m (138 kgf*cm, 10 ft.*lbf) 

  16. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 
    1. Install the front engine mounting insulator assembly with the bolt.

      Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

  17. REMOVE ENGINE SUPPORT BAR 
    1. Remove the 2 bolts and SST (support bar) from the vehicle body.
    2. Remove the nut, stud bolt and SST (support bar) from the engine mounting bracket RH.
  18. INSTALL ENGINE MOUNTING INSULATOR RH 
    1. Install the engine mounting insulator RH with the nut.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

  19. INSTALL FRONT FRAME ASSEMBLY 

    Refer to PROCEDURE - Step 15

  20. REMOVE BELT 
    1. Remove SST from the vehicle body.
      GTY722375Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the windshield washer jar assembly to the vehicle body with the bolt and nut.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

  21. REMOVE ENGINE SUPPORT BRIDGE 
    1. Remove SST from the vehicle body.
      NOTE:

      Prevent SST from contacting the vehicle body or windshield glass.

    2. Engage the air conditioner tube and accessory assembly to the piping clamp.
  22. REMOVE ENGINE HANGER 
    1. Remove the 2 bolts and No. 2 engine hanger from the cylinder head LH.
    2. Install the wire harness bracket to the engine assembly with the bolt.

      Torque: 16.5 N*m (168 kgf*cm, 12 ft.*lbf) 

    3. Remove the bolt, SST (collar) and No. 1 engine hanger from SST (engine hanger attachment).
    4. Remove the 2 bolts and SST (engine hanger attachment) from the cylinder head RH.
    5. Connect the wire harness with the bolt.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

  23. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the cylinder head RH with the bolt.

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

    2. Engage the hose clamp and 3 wire harness clamps.
    3. Connect the air fuel ratio sensor (for Bank 1) connector.
  24. CONNECT FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 

    Refer to PROCEDURE - Step 20

  25. CONNECT ENGINE MOUNTING INSULATOR LH 

    Refer to PROCEDURE - Step 21

  26. CONNECT ENGINE MOUNTING INSULATOR RH 

    Refer to PROCEDURE - Step 22

  27. CONNECT REAR ENGINE MOUNTING INSULATOR ASSEMBLY 

    Refer to PROCEDURE - Step 23

  28. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  29. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 10

  30. INSTALL FRONT DRIVE SHAFT ASSEMBLY 

    Refer to INSTALLATION [02/2014 - ]

  31. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 7

  32. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 19

  33. CONNECT WIRE HARNESS 
    1. Install the No. 3 earth wire with the bolt.

      Torque: 12 N*m (122 kgf*cm, 106 in.*lbf) 

    2. Engage the 8 clamps.
    3. Connect the motor temperature sensor connector.
    4. Connect the motor resolver sensor connector.
    5. Connect the generator resolver sensor connector.
    6. Connect the shift lever position sensor connector.
  34. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 28

  35. CONNECT NO. 3 MOTOR COOLING HOSE 

    Refer to PROCEDURE - Step 48

  36. CONNECT NO. 1 MOTOR COOLING HOSE 

    Refer to PROCEDURE - Step 49

  37. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 16

  38. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to INSTALLATION [11/2016 - ]

  39. INSTALL INVERTER TRAY BRACKET SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 39

  40. INSTALL INVERTER WITH CONVERTER ASSEMBLY 

    Refer to INSTALLATION [11/2016 - ]

  41. INSPECT FOR EXHAUST GAS LEAK 
  42. INSTALL FRONT FENDER APRON SEAL LH 

    Refer to PROCEDURE - Step 78

  43. INSTALL FRONT FENDER APRON SEAL RH 

    Refer to PROCEDURE - Step 79

  44. INSTALL FRONT FENDER LINER LH 

    Refer to PROCEDURE - Step 80

  45. INSTALL FRONT FENDER LINER RH 

    Refer to PROCEDURE - Step 81

  46. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 82

  47. INSTALL NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 83

  48. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 84

  49. INSTALL FRONT WHEELS 

    Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 

  50. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [11/2016 - ]

  51. CHECK FOR SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [11/2016 - ]

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