Click here

HYBRID VEHICLE TRANSMISSION INSTALLATION

Click here
Click here

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.

Click here

PROCEDURE


  1. Click here

    INSTALL TRANSFER ASSEMBLY

    Click here

  2. Click here

    INSTALL AUTOMATIC TRANSMISSION CASE COVER


    1. B004W4J

      Install the automatic transmission case cover with the 4 bolts.

      5.4 N*m 55 kgf*cm 48 in.*lbf
  3. Click here

    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.

      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. Click here

    INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY


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

    2. B004WJEC01
      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.

      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.

      Tip:
      Bolt Bolt Length
      A 50 mm (1.97 in.)
      B 43 mm (1.69 in.)
  5. Click here

    INSTALL REAR ENGINE MOUNTING INSULATOR


    1. B004YI2

      Install the rear engine mounting insulator with the 4 bolts.

      34 N*m 347 kgf*cm 25 ft.*lbf
  6. Click here

    INSTALL ENGINE REAR MOUNTING MEMBER


    1. B004UJL

      Install the engine rear mounting member with the 3 nuts.

      41 N*m 418 kgf*cm 30 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.

      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. Click here

    INSTALL FLYWHEEL HOUSING UNDER COVER


    1. B004S1K

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

  8. Click here

    INSTALL FLYWHEEL HOUSING SIDE COVER


    1. B004W8R

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

  9. Click here

    INSTALL STARTER HOLE INSULATOR


    1. B004R60

      Install the starter hole insulator with the 2 bolts.

      58 N*m 591 kgf*cm 43 ft.*lbf
  10. Click here

    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. B004TELC01
      *1 Oil Cooler without Hose Tube Sub-assembly *2 Oil Cooler Union Sub-assembly

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

    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.

      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. B004UW9

      Connect the 9 wire harness clamps.

    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.

  11. Click here

    INSTALL WIRE HARNESS CLAMP BRACKET


    1. B004VVZC01
      *a Protrusion
      *b Cutout

      Install the wire harness clamp bracket with the bolt.

      8.0 N*m 82 kgf*cm 71 in.*lbf
      Tip:

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

  12. Click here

    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.

        8.0 N*m 82 kgf*cm 71 in.*lbf
        Tip:

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

      2. B004TDX

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

        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.

        8.0 N*m 82 kgf*cm 71 in.*lbf
        Tip:

        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.

        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.

        8.0 N*m 82 kgf*cm 71 in.*lbf
        Tip:

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

  13. Click here

    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.

      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
  14. Click here

    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.

      7.0 N*m 71 kgf*cm 62 in.*lbf
  15. Click here

    INSTALL TRANSMISSION OIL PUMP INSULATOR


    1. B004YMP

      Install the transmission oil pump insulator with the 3 bolts.

      8.0 N*m 82 kgf*cm 71 in.*lbf
  16. Click here

    CONNECT WIRE HARNESS


    1. B004UP1C01
      B004SZX Wire Harness Connector B004UK4 Bolt

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

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Connect the 6 wire harness connectors.

  17. Click here

    INSTALL MOTOR CABLE

    Click here

  18. Click here

    INSTALL GENERATOR CABLE

    Click here

  19. Click here

    INSTALL EXHAUST MANIFOLD ASSEMBLY RH

    Click here

  20. Click here

    INSTALL EXHAUST MANIFOLD ASSEMBLY LH

    Click here

  21. Click here

    TEMPORARILY TIGHTEN FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  22. Click here

    FULLY TIGHTEN FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  23. Click here

    INSTALL NO. 1 EGR PIPE

    Click here

  24. Click here

    INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY


    1. B004RQ0

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

      43 N*m 438 kgf*cm 32 ft.*lbf
  25. Click here

    INSTALL ENGINE ASSEMBLY WITH HYBRID VEHICLE TRANSMISSION

    Click here

  26. Click here

    PERFORM INITIALIZATION

    Click here

  27. Click here

    PERFORM RESOLVER INITIALIZATION

    Click here

  28. Click here

    PERFORM RESET MEMORY

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

    Click here

  29. Click here

    CHECK VEHICLE HEIGHT CONTROL (w/ Air Suspension)

    Click here