HYBRID VEHICLE TRANSAXLE REMOVAL

Info Added 2017-10-06

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during hybrid vehicle transaxle assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Auxiliary battery terminal is disconnected/reconnected	Memorize steering angle neutral point	Lane departure alert system (w/ Steering Control)	Click here
		Simple intelligent parking assist system*1
		Toyota parking assist-sensor system*1
		Pre-crash safety system
	Initialize back door lock	Power door lock control system	Click here
Replacement of ECM	Perform Vehicle Identification Number (VIN) registration	MIL comes on	Click here
for SFI system Replacement of throttle body assembly Replacement of engine assembly Gas leak from exhaust system is repaired	Inspection after repair	Poor idle, etc. Engine start function, etc.	Click here
Front wheel alignment adjustment	Clear zero point calibration data. Perform yaw rate and acceleration sensor zero point calibration.	DTCs are stored ABS warning light illuminates Brake warning light / yellow (minor malfunction) illuminates Slip indicator light illuminates VSC disabled or malfunctions	for Initialization: Click here for Calibration: Click here
Suspension, tires, etc. (The vehicle height changes because of suspension or tire replacement)	Initialize headlight ECU sub-assembly LH	Automatic headlight beam level control system	Click here
Replacement of hybrid vehicle transaxle assembly	Resolver learning Initialize resolver	DTCs are stored Slight vibration at a vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration	Click here
Replacement of inverter with converter assembly	Resolver learning		Click here

*1: When performing learning using the GTS.

Click here

CAUTION:

Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.

Click here
To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.
*a An Object Exceeding Weight Limit of Engine Lifter

The engine assembly with hybrid vehicle transaxle assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.

PROCEDURE

PERFORM RESOLVER INITIALIZATION

Note

If it is necessary to replace the hybrid vehicle transaxle assembly, make sure to perform resolver initialization before starting work.

Click here
REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

Click here
INSTALL ENGINE HANGERS

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DISCONNECT ENGINE WIRE

Disconnect the motor revolution sensor wire connector.

*a	Motor Revolution Sensor Wire Connector	*b	Shift Lever Position Sensor
*c	Motor Temperature Sensor Connector	-	-

Disconnect the shift lever position sensor connector.
Disconnect the motor temperature sensor connector.
Remove the 2 bolts.
Disengage the 2 clamps to disconnect the engine wire from the hybrid vehicle transaxle assembly.

DISCONNECT HV AIR CONDITIONING WIRE
1. Remove the bolt.
2. Disengage the guide to disconnect the HV air conditioning wire from the hybrid vehicle transaxle assembly.
REMOVE STARTER HOLE INSULATOR
1. Remove the 2 bolts and starter hole insulator from the engine assembly.
REMOVE FLYWHEEL HOUSING SIDE COVER
1. Remove the flywheel housing side cover from the engine assembly.
REMOVE ENGINE ASSEMBLY
1. Remove the 7 bolts and engine assembly from the hybrid vehicle transaxle assembly.
  Note
  
  To avoid damaging the knock pins, do not pry between the hybrid vehicle transaxle assembly and engine assembly.
  
  To prevent the splines of the transmission input damper assembly from becoming misaligned, do not allow the hybrid vehicle transaxle assembly to hit the transmission input damper assembly during hybrid vehicle transaxle assembly removal and installation.
REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
1. Remove the bolt and front suspension crossmember sub-assembly from the No. 2 engine moving control rod.
REMOVE NO. 2 ENGINE MOVING CONTROL ROD
1. Remove the 4 bolts and No. 2 engine moving control rod from the hybrid vehicle transaxle assembly.
REMOVE MOTOR CABLE

Click here
REMOVE MOTOR COOLING COOLER
1. Slide the clip and disconnect the No. 1 motor cooling hose from the No. 1 motor cooling pipe.
2. Remove the bolt and No. 1 oil cooler tube clamp from the hose bracket.
3. Remove the union bolt and gasket to disconnect the No. 2 motor cooling pipe from the hybrid vehicle transaxle assembly.
4. Remove the 3 bolts and motor cooling cooler with No. 2 motor cooling pipe from the hybrid vehicle transaxle assembly.
  
  Note
  
  Make sure not to remove the No. 1 motor cooling hose and No. 2 motor cooling hose from the motor cooling cooler as the motor cooling cooler may be deformed.
REMOVE NO. 1 MOTOR COOLING PIPE
1. Loosen the flare nut of the No. 1 motor cooling pipe and disconnect the No. 1 motor cooling pipe from the union.
2. Remove the bolt, No. 1 oil cooler tube clamp and No. 1 motor cooling pipe from the hose bracket.
REMOVE HOSE BRACKET
1. Remove the 2 bolts and hose bracket from the hybrid vehicle transaxle assembly.
REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET
1. Remove the 2 bolts and No. 1 transmission control cable bracket from the hybrid vehicle transaxle assembly.
REMOVE WIRE HARNESS CLAMP BRACKET
1. Remove the 2 bolts and 2 wire harness clamp brackets from the hybrid vehicle transaxle assembly.
REMOVE TRANSAXLE HOUSING PLUG
1. Remove the transaxle housing plug and gasket from the hybrid vehicle transaxle assembly.