Installation [06/2020 - ]: Procedure

HINT: 

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

1. Coat 2 new O-rings with Toyota Genuine ATF WS and install them to the 2 transaxle housing tube connectors.
2. Using a 19 mm deep socket wrench, install the 2 transaxle housing tube connectors 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.

1. Install the transaxle breather plug to the hybrid vehicle transaxle assembly.

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

1. Clean and degrease the 2 stud bolts and 2 stud bolt holes.

   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 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) 

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 4 wire harness clamp brackets to the hybrid vehicle transaxle assembly with the 4 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   for bolt A 

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

   for bolt B 

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

1. Install the transmission wire to the hybrid vehicle transaxle assembly with the bolt.

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

2. Connect the connector.

1. Install the No. 3 inverter bracket to the hybrid vehicle transaxle assembly with the bolt.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Pin
   *b	Hole

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

   NOTE:

   Align the hole on the hybrid vehicle transaxle assembly with the pin of the No. 3 inverter bracket as shown in the illustration.

2. Install the 5 bolts.

   Torque: 55 N.m (561 kgf/cm, 41 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 No. 2 motor cooling pipe to the hybrid vehicle transaxle assembly with the oil cooler union bolt and a new gasket.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *1	Oil Cooler Union Bolt
   *2	Gasket

2. Temporarily install the bolt A.
3. Install the bolt B.

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

4. Tighten the bolt A.

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

5. Tighten the oil cooler union bolt.

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

1. Temporarily install the motor cooling cooler to the No. 1 transmission control cable bracket with the 3 bolts.

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

   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)

   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  1

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 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.

   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 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   for bolt A 

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

   for bolt B and bolt C 

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

   for bolt D 

   Torque: 25 N.m (255 kgf/cm, 18 ft.lbf) 

   HINT: 

   Bolt	Bolt Length
   A	50 mm (1.97 in.)
   B and C	45 mm (1.77 in.)
   D	35 mm (1.38 in.)

   • Bolt A, B and D: Install from the hybrid vehicle transaxle assembly side.
   • Bolt C: Install from the engine assembly side.

1. Install the No. 1 engine mounting bracket to the hybrid vehicle transaxle assembly with the 4 bolts.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 42 N.m (428 kgf/cm, 31 ft.lbf) 

   HINT: 

   Tightening order: Temporarily install bolt A → Tighten bolt B → Tighten bolt A → Tighten bolt C

Refer to PROCEDURE - Step 15

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 42 N.m (428 kgf/cm, 31 ft.lbf) 

   HINT: 

   Tightening order: Temporarily install bolt A → Tighten bolt B → Tighten bolt C → Tighten bolt A

1. Install the front engine mounting insulator to the front engine mounting bracket with the bolt.

   Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

Refer to PROCEDURE - Step 6

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

1. Install the No. 1 transmission oil cooler hose assembly to the No. 2 motor cooling pipe and transaxle housing tube connector, slide the 2 clips to secure it.
   NOTE:

   • Make sure to slide the No. 1 transmission oil cooler hose assembly until it contacts the hose stopper of the No. 2 motor cooling pipe and transaxle housing tube connector.
   • Make sure to align the paint mark of the No. 1 transmission oil cooler hose assembly with the paint mark of the No. 2 motor cooling pipe.
   • Make sure to align the paint mark of the No. 1 transmission oil cooler hose assembly 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.

   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)

2. Engage the hose clamp to connect the No. 1 transmission oil cooler hose assembly to the bracket.

See step  1

1. Temporarily install the flare nut of a new No. 1 motor cooling pipe to the union.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Torque Wrench Fulcrum Length

2. Install the No. 2 oil cooler tube clamp and No. 1 motor cooling pipe to the No. 2 motor cooling pipe with the bolt.

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

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

   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 [06/2020 - ]

   • 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. Engage the hose clamp to install the No. 2 transmission oil cooler hose assembly to the No. 2 motor cooling pipe.

   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)
   *g	30° (Center of Clip Location)	-	-

2. Connect the No. 2 transmission oil cooler hose assembly to the No. 1 motor cooling pipe and slide the clip to secure it.
   NOTE:

   • Make sure to slide the No. 2 transmission oil cooler hose assembly until it contacts the hose stopper of the No. 1 motor cooling pipe.
   • Make sure to align the paint mark of the No. 2 transmission oil cooler hose assembly with the paint mark of the No. 1 motor cooling pipe.
   • Make sure that the claws of the clip are within the location shown in the illustration.
3. Connect the No. 2 transmission oil cooler hose assembly to the motor cooling cooler and slide the clip to secure it.
   NOTE:

   • Make sure to slide the No. 2 transmission oil cooler hose assembly until it contacts the hose stopper of the motor cooling cooler.
   • Make sure to align the paint mark of the No. 2 transmission oil cooler hose assembly with the paint mark of the motor cooling cooler.
   • Make sure that the claws of the clip are within the location shown in the illustration.
4. Connect the No. 2 transmission oil cooler hose assembly to the oil pump with motor assembly and slide the 2 clips to secure it.
   NOTE:

   • Make sure to slide the No. 2 transmission oil cooler hose assembly until it contacts the hose stopper of the oil pump with motor assembly.
   • Make sure to align the paint mark on each No. 2 transmission oil cooler hose assembly with each marking on the oil pump with motor assembly.
   • Make sure that the claws of the clip are within the location shown in the illustration.

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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

   HINT: 

   Tightening order: Temporarily install bolt A → Tighten bolt B → Tighten bolt C → Tighten bolt A

1. Engage the guide to connect the HV air conditioning wire to the hybrid vehicle transaxle assembly.
2. Connect the HV air conditioning wire to the hybrid vehicle transaxle assembly with the 2 bolts.

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

1. for Front Side:
   1. Connect the engine wire with the bolt.

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

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

2. for Rear Side:
   1. Engage the 6 clamps to connect the engine wire.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Rotating the lock lever

      Engage the lock

   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 PROCEDURE - Step 7

Refer to INSTALLATION [06/2020 - ]