HYBRID VEHICLE TRANSMISSION INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transmission is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed.

Therefore, always follow the instructions listed in the repair manual when performing this procedure.

PROCEDURE


  1. INSTALL AUTOMATIC TRANSMISSION CASE COVER


    1. B004S8V

      Install the automatic transmission case cover with the 4 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  2. INSTALL DYNAMIC DAMPER

    Note

    B004SRFC01
    *a Upper Side
    *b RH Side

    Check the installation direction of the dynamic damper before installing it.


    1. B004T87

      Using a T40 ''TORX'' socket wrench, install the dynamic damper with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. B004TAK

      Using a T40 ''TORX'' socket wrench, install the dynamic damper with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  3. INSTALL BRACKET


    1. B004SIQC01
      *1 No. 3 Wiring Harness Clamp Bracket
      *2 No. 2 Wiring Harness Clamp Bracket
      *3 Wiring Harness Clamp Bracket
      *4 No. 1 Wiring Harness Clamp Bracket
      *5 Transmission Oil Pump Insulator Bracket
      *6 No. 2 Heat Insulator Bracket
      B004SZX Bolt A
      B004UK4 Bolt B
      B004XCB Bolt C

      Install the 6 brackets with the 6 bolts.

      Torque:
      for bolt A
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
      for bolt B
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for bolt C
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  4. INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY


    1. Make sure that the knock pins are installed on the engine assembly.

    2. B004WPAC01
      B004SZX Bolt A
      B004UK4 Bolt B

      Install the hybrid vehicle transmission assembly to the engine assembly with the 9 bolts as shown in the illustration.

      Torque:
      for bolt A
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }
      for bolt B
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

      CAUTION:


      • Do not raise the hybrid vehicle transmission assembly more than necessary.

      • Make sure to confirm the center of the gravity of the hybrid vehicle transmission assembly when supporting it.

      Note


      • Before tightening, check that the contact surfaces of the engine assembly and hybrid vehicle transmission assembly are in close contact.

      • Do not apply grease either to the splines or input shaft.

      Tech Tips

      Bolt Bolt Length
      A 50 mm (1.97 in.)
      B 43 mm (1.69 in.)

  5. INSTALL REAR ENGINE MOUNTING INSULATOR


    1. B004XN1

      Install the rear engine mounting insulator with the 4 bolts.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  6. INSTALL ENGINE REAR MOUNTING MEMBER


    1. B004VW6

      Install the engine rear mounting member with the 3 nuts.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }
    2. B004TQRC01
      B004SZX Bolt
      B004UK4 Nut and Spring Washer

      Connect the No. 2 parking lock release cable assembly to the shift control actuator assembly with the nut, spring washer and 2 bolts.

      Torque:
      for bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for nut
      12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }

  7. INSTALL FLYWHEEL HOUSING SIDE COVER


    1. B004W8R

      Install the flywheel housing side cover to the engine assembly as shown in the illustration.

  8. INSTALL STARTER HOLE INSULATOR


    1. B004WOX

      Install the starter hole insulator with the 2 bolts.

      Torque:
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }

  9. INSTALL OIL COOLER WITHOUT HOSE TUBE SUB-ASSEMBLY


    1. B004RRF

      Install the No. 1 oil cooler outlet hose to the oil cooler without hose tube sub-assembly and oil cooler union sub-assembly, and slide the 2 clips to secure the hose.

      Note


      • When connecting the No. 1 oil cooler outlet hose, align with the colors and positions of the paint mark before connecting.

      • After connecting the No. 1 oil cooler outlet hose, check that the hose is not twisted.

    2. B004USI

      Install the No. 1 oil cooler inlet hose to the oil cooler without hose tube sub-assembly and oil cooler union sub-assembly, and slide the 2 clips to secure the hose.

      Note


      • When connecting the No. 1 oil cooler inlet hose, align with the colors and positions of the paint mark before connecting.

      • After connecting the No. 1 oil cooler inlet hose, check that the hose is not twisted.

    3. B004UK9

      Install the No. 2 oil cooler outlet hose to the oil cooler without hose tube sub-assembly, and slide the clip to secure the hose.

      Note


      • When connecting the No. 2 oil cooler outlet hose, align with the colors and positions of the paint mark before connecting.

      • After connecting the No. 2 oil cooler outlet hose, check that the hose is not twisted.

    4. B004WWV

      Install the No. 2 oil cooler inlet hose to the oil cooler without hose tube sub-assembly, and slide the clip to secure the hose.

      Note


      • When connecting the No. 2 oil cooler inlet hose, align with the colors and positions of the paint mark before connecting.

      • After connecting the No. 2 oil cooler inlet hose, check that the hose is not twisted.

    5. Temporarily install the oil cooler union sub-assembly with the 2 union bolts, 4 new gaskets and 2 bolts (B).

      B004YQGC01
      *1 Oil Cooler without Hose Tube Sub-assembly *2 Oil Cooler Union Sub-assembly

    6. Temporarily install the oil cooler without hose tube sub-assembly with the 2 bolts (A).

    7. Tighten the 2 union bolts and 4 bolts.

      Torque:
      for union bolt
      27.5 N*m  { 280 kgf*cm, 20 ft.*lbf }
      for bolt
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    8. Connect the 9 wire harness clamps.

      B004UBP

    9. Connect the oil pump thermistor connector.

    10. B004XXE

      Connect the No. 2 oil cooler inlet hose to the motor cooling cooler, and slide the clip to secure the hose.

      Note


      • When connecting the No. 2 oil cooler inlet hose, align with the colors and positions of the paint mark before connecting.

      • After connecting the No. 2 oil cooler inlet hose, check that the hose is not twisted.

      • Do not deform the motor cooling cooler.

  10. INSTALL WIRE HARNESS CLAMP BRACKET


    1. B004VVZC01
      *a Protrusion
      *b Cutout

      Install the wire harness clamp bracket with the bolt.

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

      Tech Tips

      Align the cutout with the protrusion as shown in the illustration.

  11. INSTALL ENGINE MOTOR CABLE CLAMP BRACKET


    1. for LHD:


      1. B004VHIC01
        *a Protrusion
        *b Cutout

        Install the engine motor cable clamp bracket with the bolt.

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

        Tech Tips

        Align the cutout with the protrusion as shown in the illustration.

      2. B004TDX

        Install the engine motor cable clamp bracket with the 2 bolts.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      3. B004S9ZC01
        *a Protrusion
        *b Hole

        Install the engine motor cable clamp bracket with the bolt.

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

        Tech Tips

        Align the hole with the protrusion as shown in the illustration.

    2. for RHD:


      1. B004VSP

        Install the engine motor cable clamp bracket with the 2 bolts.

        Torque:
        8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      2. B004YFDC01
        *a Protrusion
        *b Cutout

        Install the engine motor cable clamp bracket with the bolt.

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

        Tech Tips

        Align the cutout with the protrusion as shown in the illustration.

  12. INSTALL NO. 1 TRANSMISSION BREATHER ASSEMBLY


    1. B004RQOC01
      *1 No. 1 Transmission Breather Assembly
      *2 Transmission Breather Hose

      Install the transmission breather hose to the No. 1 transmission breather assembly, and slide the clip to secure the hose.

      Note


      • Install the long side of the transmission breather hose to the breather tube.

        Side B of the transmission breather hose is longer than side A.

      • Install the clip facing upwards so that it does not interfere with other parts when the No. 1 transmission breather assembly is installed to the hybrid vehicle transmission assembly.

      • Check that the clip is not interfering with other parts after installing the No. 1 transmission breather assembly to the hybrid vehicle transmission.

    2. B004RA2C01
      B004SZX Bolt A
      B004UK4 Bolt B

      Install the No. 1 transmission breather assembly with the 2 bolts and connect the 3 clamps.

      Torque:
      for bolt A
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
      for bolt B
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

  13. INSTALL NO. 2 TRANSMISSION BREATHER ASSEMBLY


    1. Coat a new O-ring with Toyota Genuine ATF WS.

    2. B004U7M

      Install the O-ring to the No. 2 transmission breather assembly.

    3. B004RTY

      Install the No. 2 transmission breather assembly with the bolt and connect the 4 clamps.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  14. INSTALL TRANSMISSION OIL PUMP INSULATOR


    1. B004YMP

      Install the transmission oil pump insulator with the 3 bolts.

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

  15. CONNECT WIRE HARNESS


    1. Connect the wire harness to the hybrid vehicle transmission assembly with the 6 bolts and connect the 5 wire harness clamps.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      B004S0XC01
      B004SZX Wire Harness Connector B004UK4 Bolt

    2. Connect the 6 wire harness connectors.

  16. INSTALL MOTOR CABLE

    Click here

  17. INSTALL GENERATOR CABLE

    Click here

  18. INSTALL EXHAUST MANIFOLD ASSEMBLY RH

    Click here

  19. INSTALL EXHAUST MANIFOLD ASSEMBLY LH

    Click here

  20. INSTALL NO. 1 EGR PIPE

    Click here

  21. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY


    1. B004YDV

      Install the No. 1 exhaust pipe support bracket sub-assembly with the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  22. INSTALL ENGINE ASSEMBLY WITH HYBRID VEHICLE TRANSMISSION

    Click here

  23. PERFORM INITIALIZATION

    Click here

  24. PERFORM RESOLVER INITIALIZATION

    Click here

  25. PERFORM RESET MEMORY

    If the hybrid vehicle transmission assembly is replaced, initialize the learning value of the transmission.

    Click here

  26. CHECK VEHICLE HEIGHT CONTROL (w/ Air Suspension)

    Click here