HYBRID VEHICLE TRANSMISSION INSTALLATION

PROCEDURE


  1. INSTALL WIRE HARNESS CLAMP


    1. Align the matchmarks and install 9 new clamps to the wire.

      A000VG3E03

  2. INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY


    1. A000TTNE03
      *1 Knock Pin

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

    2. While keeping the engine and the hybrid vehicle transmission assembly horizontal, align the knock pins and the knock pin holes, and then tighten the 10 bolts 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 }

      Note


      • Do not forcibly pry out the hybrid vehicle transmission assembly.

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

      Bolt Diameter Bolt length
      A 12 mm (0.47 in.) 50 mm (1.97 in.)
      B 10 mm (0.39 in.) 43 mm (1.69 in.)

  3. INSTALL STARTER HOLE INSULATOR


    1. A000XJ5

      Install the starter hole insulator with the 2 bolts.

      Torque:
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }
      Diameter Bolt length
      10 mm (0.39 in.) 65 mm (2.56 in.)

  4. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. Install the breather hose.

    2. A000YQYE02
      *1 for LHD:
      *2 for RHD:

      Install the transmission breather hose with the 2 bolts.

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

    3. Connect the clamp and clip.

  5. INSTALL NO. 1 HV WATER PUMP OUTLET PIPE (for LHD)


    1. A000VIT

      Install the No. 1 hv water pump outlet pipe with the 2 bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    2. Secure the hose with the clip.

  6. INSTALL NO. 2 MOTOR COOLING PIPE (for RHD)


    1. A000W29

      Install the No. 2 motor cooling pipe with the 2 bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    2. Secure the hose with the clip.

  7. INSTALL NO. 1 MOTOR COOLING PIPE (for LHD)


    1. A000VK1

      Install the No. 1 motor cooling pipe with the 2 bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    2. Secure the hose with the clip.

      Note

      Do not install the clip close to the outlet port of the union pipe.

  8. INSTALL NO. 1 INVERTER COOLING PIPE (for RHD)


    1. A000VK1

      Install the No. 1 inverter cooling pipe with the 2 bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    2. Secure the hose with the clip.

      Note

      Do not install the clip close to the outlet port of the union pipe.

  9. INSTALL REAR NO. 2 ENGINE MOUNTING INSULATOR


    1. A000XGY

      Install the mounting insulator with the 2 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  10. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR


    1. A000Z5V

      Install the 2 mounting insulators with the 4 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  11. INSTALL REAR ENGINE MOUNTING MEMBER


    1. A000X31

      Install the mounting member and No. 3 mounting insulator with the 5 nuts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  12. INSTALL GENERATOR CABLE PROTECTOR


    1. for LHD:


      1. Align the matchmarks and install the 3 generator cable protectors to the generator cable.

        A000TK3E01

        Note

        Install the protectors to the positions indicated by the matchmarks that placed before removing the protectors.

    2. for RHD:


      1. Align the matchmarks and install the 2 generator cable protectors to the generator cable.

        A000ZBL

        Note

        Install the protectors to the positions indicated by the matchmarks that placed before removing the protectors.

  13. INSTALL MOTOR CABLE PROTECTOR


    1. for LHD:


      1. Align the matchmarks and install the 3 motor cable protectors to the motor cable.

        A000U6M

        Note

        Install the protectors to the positions indicated by the matchmarks that placed before removing the protectors.

    2. for RHD:


      1. Align the matchmarks and install the 4 motor cable protectors to the motor cable.

        A000WDNE01

        Note

        Install the protectors to the positions indicated by the matchmarks that placed before removing the protectors.

  14. INSTALL MOTOR CABLE

    Note

    When installing the motor cable, minimize bending of the cable end on the transmission side.


    1. A000Y56

      Install the 3 O-rings to the terminal cables.

      Note


      • Make sure that the O-rings are not damaged.

      • Do not allow the O-rings to rest out of the grooves.

      • Do not allow any ATF to adhere to the O-rings.

      • Make sure that the O-rings are not twisted.

    2. A000YQ0

      Using a 5 mm hexagon wrench, tighten the 3 bolts.

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

      Note


      • When installing the motor cable, align the projections on the cable with the terminal grooves.

      • Do not apply force to the cable when installing it.

      • Do not allow the cable to twist when installing it.

      • When installing the motor cable, minimize bending of the cable end on the transmission side.

      • Protect the terminal cables and the installation components from water or foreign objects.

      • Make sure that the O-rings do not get pinched between the parts.

      • Make sure that the tightening torque is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

      Tech Tips

      To avoid putting too much pressure on the motor cable and bending its end, hold the end of the motor cable in one hand and use the other hand to line the motor cable up and install it against the side of the engine.

    3. Install the 2 bolts.

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

      Note

      Make sure that the tightening torque is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

    4. A000ZV1

      Install 3 new terminal caps to the hybrid vehicle transmission assembly.

      Note


      • Make sure that the O-rings are not damaged.

      • Do not allow any ATF to adhere to the O-rings.

      • Make sure that the O-rings are not twisted.

      • Make sure that the O-rings do not get pinched between the parts.

      • After installing the terminal caps, make sure that the locks are securely engaged.

    5. A000YPZ

      Install the connector cover with the 2 bolts.

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

      Note

      Make sure that the tightening torque is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

  15. INSTALL GENERATOR CABLE

    Note

    When installing the generator cable, minimize bending of the cable end on the transmission side.


    1. A000Y56

      Install the 3 O-rings to the terminal cables.

      Note


      • Make sure that the O-rings are not damaged.

      • Do not allow the O-rings to rest out of the grooves.

      • Do not allow any ATF to adhere to the O-rings.

      • Make sure that the O-rings are not twisted.

    2. A000Y5S

      Using a 5 mm hexagon wrench, tighten the 3 bolts.

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

      Note


      • When installing the generator cable, align the projections on the cable with the terminal grooves.

      • Do not apply force to the cable when installing it.

      • Do not allow the cable to twist when installing it.

      • Protect the terminal cables and the installation components from water or foreign objects.

      • Make sure that the O-rings do not get pinched between the parts.

      • Make sure that the tightening torque is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

      Tech Tips

      To avoid putting too much pressure on the generator cable and bending its end, hold the end of the generator cable in one hand and use the other hand to line the generator cable up and install it against the side of the engine.

    3. Install the 2 bolts.

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

      Note

      Make sure that the tightening torque is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

    4. A000VUL

      Install 3 new terminal caps to the hybrid vehicle transmission assembly.

      Note


      • Make sure that the O-rings are not damaged.

      • Do not allow any ATF to adhere to the O-rings.

      • Make sure that the O-rings are not twisted.

      • Make sure that the O-rings do not get pinched between the parts.

      • After installing the terminal caps, make sure that the locks are securely engaged.

    5. A000XQL

      Install the connector cover with the 2 bolts.

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

      Note

      Make sure that the tightening torque is between 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

  16. INSTALL OIL COOLER TUBE


    1. Install the oil cooler tube with the 2 clips and the 3 bolts in the order shown in the illustration.

      A000WAXE02
      *a for RHD:
      *b for LHD:
      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  17. INSTALL TRANSMISSION MOTOR CABLE CLAMP BRACKET


    1. A000YFU

      Install the transmission motor cable clamp bracket with the bolt.

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

  18. CONNECT WIRE HARNESS

    Note

    When installing the motor cable and generator cable, minimize bending of the cable end on the transmission side.


    1. for LHD:


      1. Install the wire harness with the 6 bolts.

        A000W1V
        Torque:
        10 N*m  { 102 kgf*cm, 9 ft.*lbf }

      2. Connect the 15 clamps.

      3. A000YZP

        Install the 2 ground cables with the 2 bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 9 ft.*lbf }

    2. for RHD:


      1. Install the wire harness with the 8 bolts.

        A000UO7
        Torque:
        10 N*m  { 102 kgf*cm, 9 ft.*lbf }

      2. Connect the 15 clamps.

      3. A000U97

        Install the 2 ground cables with the 2 bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 9 ft.*lbf }

  19. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY


    1. A000TO3E02
      *1 for RHD:
      *2 for LHD:

      Install a new O-ring.

    2. Coat the O-ring with ATF.

    3. Install the transmission breather hose sub-assembly.

    4. Connect the clamp.

  20. CONNECT CONNECTOR


    1. for LHD:


      1. Connect the 11 wire harness connectors.

        A00104H

    2. for RHD:


      1. Connect the 11 wire harness connectors.

        A000TVS

  21. INSTALL NO. 3 COVER SUB-ASSEMBLY


    1. A000VBLE02
      *1 for LHD:
      *2 for RHD:

      Install the No. 3 cover sub-assembly with the 2 clips.

  22. INSTALL INVERTER MOTOR CABLE CLAMP BRACKET


    1. for LHD:


      1. A000UUR

        Install the 2 inverter motor cable clamp brackets to the motor cable.

      2. Connect the generator cable to the motor cable.

    2. for RHD:


      1. A000U3R

        Install the 2 inverter motor cable clamp brackets to the motor cable.

  23. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  24. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET LH

    Click here

  25. INSTALL FRONT NO. 2 ENGINE MOUNTING BRACKET RH

    Click here

  26. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  27. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  28. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

    Click here

  29. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH

    Click here

  30. INSTALL FRONT ENGINE MOUNTING INSULATOR

    Click here

  31. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  32. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  33. INSTALL OIL LEVEL DIPSTICK GUIDE

    Click here

  34. INSTALL FRONT FRAME ASSEMBLY

    Click here

  35. INSTALL ENGINE AND TRANSMISSION


    1. Install the engine and transmission Click here.

  36. INSPECT AND ADJUST TRANSMISSION FLUID

    Click here.

  37. PERFORM RESET MEMORY

    Initialize the learned value of RESET MEMORY Click here.