HYBRID VEHICLE TRANSAXLE INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

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.

PROCEDURE

INSTALL TRANSAXLE HOUSING PLUG
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 }
INSTALL WIRE HARNESS CLAMP BRACKET
1. Install the 3 wire harness clamp brackets to the hybrid vehicle transaxle assembly with the 3 bolts.
  
  Torque:
  
  12.5 N*m { 127 kgf*cm, 9 ft.*lbf }
INSTALL HOSE BRACKET
1. Install the hose bracket to the hybrid vehicle transaxle assembly with the 2 bolts.
  
  Torque:
  
  11.5 N*m { 117 kgf*cm, 8 ft.*lbf }
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:
  
  12.5 N*m { 127 kgf*cm, 9 ft.*lbf }
INSTALL NO. 1 MOTOR COOLING PIPE
1. Temporarily install the No. 1 motor cooling pipe to the union with the flare nut.
2. Install the No. 1 oil cooler tube clamp to the hose bracket with the bolt.
  
  Torque:
  
  11.5 N*m { 117 kgf*cm, 8 ft.*lbf }
3. *a Torque Wrench Fulcrum Length
  
  Using a 17 mm union nut wrench, tighten the flare nut to install the No. 1 motor cooling pipe.
  
  Torque:
  
  Specified Tightening Torque
  
  34.3 N*m { 350 kgf*cm, 25 ft.*lbf }
  Tech Tips
  - Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
    
    Click here
  - 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)
INSTALL MOTOR COOLING COOLER
1. Temporarily install the motor cooling cooler with No. 2 motor cooling pipe to the hybrid vehicle transaxle assembly with the 3 bolts.
2. Tighten the 3 bolts in the order shown in the illustration.
  
  Torque:
  
  11.5 N*m { 117 kgf*cm, 8 ft.*lbf }
3. Temporarily install the No. 2 motor cooling pipe to the hybrid vehicle transaxle assembly with the union bolt and a new gasket.
4. Install the No. 1 oil cooler tube clamp to the hose bracket with the bolt.
  
  Torque:
  
  11.5 N*m { 117 kgf*cm, 8 ft.*lbf }
5. Tighten the union bolt to install the No. 2 motor cooling pipe.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
6. *a 2 to 7 mm (0.0787 to 0.276 in.)
  
  *b Paint Mark
  
  Connect the No. 1 motor cooling hose to the No. 1 motor cooling pipe and slide the clip to secure it.
  
  Note
  
  Make sure to align the paint mark on the No. 1 motor cooling pipe with the paint mark on the No. 1 motor cooling hose.
INSTALL MOTOR CABLE

Click here
INSTALL NO. 2 ENGINE MOVING CONTROL ROD
1. Install the No. 2 engine moving control rod to the hybrid vehicle transaxle assembly with the 4 bolts.
  
  Torque:
  
  44 N*m { 449 kgf*cm, 32 ft.*lbf }
  
  Note
  
  Temporarily tighten the bolt (A), and then fully tighten the 4 bolts in the order of (B), (C) and (A).
INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
1. Install the front suspension crossmember sub-assembly to the No. 2 engine moving control rod with the bolt.
  
  Torque:
  
  170 N*m { 1734 kgf*cm, 125 ft.*lbf }
INSTALL ENGINE ASSEMBLY
1. *1 Knock Pin
  
  Make sure that the knock pins are installed to the engine assembly.
2. Install the engine assembly to the hybrid vehicle transaxle assembly with the 7 bolts.
  
  Torque:
  
  33 N*m { 337 kgf*cm, 24 ft.*lbf }
  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.
  
  Temporarily tighten the bolt (A), and then fully tighten the 7 bolts in the order of (B), (A) and (C).
  
  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.
INSTALL FLYWHEEL HOUSING SIDE COVER
1. Install the flywheel housing side cover to the engine assembly.
INSTALL STARTER HOLE INSULATOR
1. Install the starter hole insulator to the engine assembly with the 2 bolts.
  
  Torque:
  
  37 N*m { 377 kgf*cm, 27 ft.*lbf }
CONNECT HV AIR CONDITIONING WIRE
1. Engage the guide to connect the HV air conditioning wire to the hybrid vehicle transaxle assembly.
2. Install the bolt.
  
  Torque:
  
  12.5 N*m { 127 kgf*cm, 9 ft.*lbf }

CONNECT ENGINE WIRE

Engage the 2 clamps to connect the engine wire to the hybrid vehicle transaxle assembly.

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

Install the 2 bolts.

Torque:

Bolt (A)

8.0 N*m { 82 kgf*cm, 71 in.*lbf }

Bolt (B)

12 N*m { 122 kgf*cm, 9 ft.*lbf }
Connect the motor temperature sensor connector.
Connect the shift lever position sensor connector.
Connect the motor revolution sensor wire connector.

INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

Click here
PERFORM RESOLVER LEARNING

Note

If the hybrid vehicle transaxle assembly, make sure to perform resolver learning.

Click here

*a	2 to 7 mm (0.0787 to 0.276 in.)
*b	Paint Mark