HYBRID VEHICLE TRANSAXLE UNIT REASSEMBLY


  1. INSTALL STRAIGHT PIN


    1. A01JA3Q

      Using a plastic hammer, install the 2 straight pins to the hybrid vehicle motor assembly.

      Standard Protrusion
      7.0 to 8.5 mm (0.276 to 0.335 in.)

  2. INSTALL RADIAL BALL BEARING


    1. Install radial ball bearing (LH side):


      1. A01JBHPE01

        Using SST and a press, install the radial ball bearing (LH side) to the counter driven gear sub-assembly.

        SST
        09316-60011   ( 09316-00011, 09316-00071 )

        Note

        Be sure to install the radial ball bearing (LH side) so that there is no clearance between the radial ball bearing (LH side) and the counter driven gear sub-assembly.

    2. Install radial ball bearing (RH side):


      1. A01JAHYE01

        Using SST and a press, install the radial ball bearing (RH side) to the counter driven gear sub-assembly.

        SST
        09316-60011   ( 09316-00011, 09316-00071 )

        Note

        Be sure to install the radial ball bearing (RH side) so that there is no clearance between the radial ball bearing (RH side) and the differential drive pinion.

  3. INSTALL TAPERED ROLLER BEARING


    1. Install tapered roller bearing (LH side):


      1. A01J9UCE01

        Using SST and a press, install the tapered roller bearing (LH side) to the differential case sub-assembly.

        SST
        09316-60011   ( 09316-00011 )

        Note

        Be sure to install the tapered roller bearing (LH side) so that there is no clearance between the tapered roller bearing (LH side) and the differential case sub-assembly.

    2. Install tapered roller bearing (RH side):


      1. A01JAAME01

        Using SST and a press, install the tapered roller bearing (RH side) to the differential case sub-assembly.

        SST
        09316-60011   ( 09316-00011 )

        Note

        Be sure to install the tapered roller bearing (RH side) so that there is no clearance between the tapered roller bearing (RH side) and the differential case sub-assembly.

  4. INSTALL TAPERED ROLLER BEARING (LH SIDE OUTER RACE)


    1. A01J91VE01

      Using SST and hammer, install the tapered roller bearing (LH side outer race) to the hybrid vehicle motor assembly.

      SST
      09950-60020   ( 09951-00750 )
      09950-70010   ( 09951-07200 )

      Note


      • If the tapered roller bearing (LH side outer race) is deformed or damaged, replace it with a new one.

      • Be sure to install the tapered roller bearing (LH side outer race) so that there is no clearance between the tapered roller bearing (LH side outer race) and the hybrid vehicle motor assembly.

  5. INSTALL TAPERED ROLLER BEARING (RH SIDE OUTER RACE)


    1. A01JB54E01

      Using SST and hammer, install the tapered roller bearing (RH side outer race) and differential case RH shim to the hybrid vehicle generator assembly.

      SST
      09950-60020   ( 09951-00750 )
      09950-70010   ( 09951-07200 )

      Note


      • If the differential case RH shim or tapered roller bearing (RH side outer race) is deformed or damaged, replace it with a new one.

      • Be sure to install the tapered roller bearing (RH side outer race) so that there is no clearance between the tapered roller bearing (RH side outer race) and the hybrid vehicle generator assembly.

  6. ADJUST PRELOAD


    1. A01JC1C

      Install the differential case sub-assembly to the hybrid vehicle motor assembly.

    2. Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts and washer as shown in the illustration.

      A01J90EE01
      Text in Illustration
      *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger
      *3 Washer - -
      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Part Name Part No.
      No. 1 engine hanger 12281-37050
      No. 2 engine hanger 12282-37040
      Bolt 91552-81050

      Tech Tips

      When installing the No. 1 engine hanger, use a washer with an appropriate thickness so that the No. 1 engine hanger will not interfere with the installation surface of the transaxle housing.

    3. Using the sling device and chain block, install the hybrid vehicle generator assembly to the hybrid vehicle motor assembly.

    4. A01J9VS

      Install the 8 bolts to the hybrid vehicle generator assembly.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

    5. Install the 2 bolts to the hybrid vehicle motor assembly.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    6. A01JAGX

      Install the 8 bolts to the hybrid vehicle generator assembly.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    7. A01JBRME01

      Using SST and a torque wrench, measure the starting torque of the differential case sub-assembly.

      SST
      09564-33010
      Standard Preload
      Starting Torque New tapered roller bearing 1.3 to 2.9 N*m (13 to 30 kgf*cm, 12 to 26 in.*lbf)
      Reused tapered roller bearing 0.9 to 2.3 N*m (9 to 23 kgf*cm, 8 to 20 in.*lbf)

      Note


      • Before measurement, turn the differential pinion shaft in both directions to settle the bearings.

      • If the differential case RH shim or tapered roller bearing (outer race) is deformed or damaged, replace it with a new one.

      Tech Tips

      If the value is not as specified, replace the differential case RH shim with one of the correct thickness.

      <Differential Case RH Shim Thickness>
      Part No. Thickness (mm (in.)) Part No. Thickness (mm (in.))
      90564-64031 1.70 (0.0669) 90564-64039 2.10 (0.0827)
      90564-64047 1.725 (0.0679) 90564-64055 2.125 (0.0837)
      90564-64032 1.75 (0.0689) 90564-64040 2.15 (0.0846)
      90564-64048 1.775 (0.0699) 90564-64056 2.175 (0.0856)
      90564-64033 1.80 (0.0709) 90564-64041 2.20 (0.0866)
      90564-64049 1.825 (0.0719) 90564-64057 2.225 (0.0876)
      90564-64034 1.85 (0.0728) 90564-64042 2.25 (0.0886)
      90564-64050 1.875 (0.0738) 90564-64058 2.275 (0.0896)
      90564-64035 1.90 (0.0748) 90564-64043 2.30 (0.0906)
      90564-64051 1.925 (0.0758) 90564-64059 2.325 (0.0915)
      90564-64036 1.95 (0.0768) 90564-64044 2.35 (0.0925)
      90564-64052 1.975 (0.0778) 90564-64060 2.375 (0.0935)
      90564-64037 2.00 (0.0787) 90564-64045 2.40 (0.0945)
      90564-64053 2.025 (0.0797) 90564-64061 2.425 (0.0955)
      90564-64038 2.05 (0.0807) 90564-64046 2.45 (0.0965)
      90564-64054 2.075 (0.0817) - -

    8. Remove the 18 bolts from the hybrid vehicle motor assembly and hybrid vehicle generator assembly.

    9. A01JBR8

      While lifting the hybrid vehicle generator assembly with a chain, tap the areas shown in the illustration with a plastic hammer and separate the hybrid vehicle generator assembly from the hybrid vehicle motor assembly.

    10. While lifting the hybrid vehicle generator assembly with a chain, remove it from the hybrid vehicle motor assembly.

      Note


      • Lift the hybrid vehicle generator assembly straight up.

      • If the hybrid vehicle generator assembly is tilted, return it to the original position before removing.

    11. Remove the differential case sub-assembly from the hybrid vehicle motor assembly.

    12. Remove the 2 bolts, washer, No. 1 engine hanger and No. 2 engine hanger from the hybrid vehicle generator assembly.

  7. INSTALL SHIFT CONTROL ACTUATOR SEAL


    1. A01JAPJE01

      Using SST and hammer, install a new shift control actuator seal to the hybrid vehicle motor assembly.

      SST
      09950-60010   ( 09951-00210 )
      09950-70010   ( 09951-07100 )
      Standard Depth
      8.5 to 9.8 mm (0.335 to 0.386 in.)

    2. Coat the lip of the shift control actuator seal with a small amount of MP grease.

  8. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL (for LH Side)


    1. A01JCX7E01

      Using SST and hammer, install a new hybrid vehicle transaxle assembly type T oil seal to the hybrid vehicle motor assembly.

      SST
      09608-32010
      09950-70010   ( 09951-07150 )
      Standard Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note


      • Do not allow foreign matter to attach to the hybrid vehicle transaxle assembly type T oil seal lip.

      • Do not install the hybrid vehicle transaxle assembly type T oil seal at an angle.

    2. Coat the lip of the hybrid vehicle transaxle assembly type T oil seal with a small amount of MP grease.

  9. INSTALL TRANSMISSION OIL STRAINER


    1. A01JB1L

      Coat a new O-ring with ATF and install it to the transmission oil strainer.

    2. A01J953E01
      Text in Illustration
      *a Detent
      *b Rib

      Install the transmission oil strainer to the hybrid vehicle motor assembly with the bolt.

      Note

      Place the detent of the transmission oil strainer to the rib.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

  10. INSTALL REAR PLANETARY SUN GEAR


    1. A01JAJO

      Install the rear planetary sun gear to the hybrid vehicle motor assembly.

    2. A01J9MI

      Using a snap ring expander, install a new rear planetary sun gear shaft snap ring to the hybrid vehicle motor assembly.

      Note

      Do not expand the rear planetary sun gear shaft snap ring excessively.

      Tech Tips

      Turn the transaxle case sideways, pull out the rotor shaft, and install the rear planetary sun gear shaft snap ring.

    3. A01JC6Y

      Turn the rear planetary sun gear shaft snap ring and check that it is not loose.

  11. INSTALL NO. 1 REAR PLANETARY GEAR ASSEMBLY


    1. A01J9VP

      Install the No. 1 rear planetary gear assembly to the rear planetary sun gear.

  12. INSTALL COUNTER DRIVE GEAR SUB-ASSEMBLY


    1. A01JBEL

      Install the counter drive gear sub-assembly to the No. 1 rear planetary gear assembly.

  13. INSTALL COUNTER DRIVEN GEAR SUB-ASSEMBLY


    1. A01J9UM

      Install the counter driven gear sub-assembly to the hybrid vehicle motor assembly.

  14. INSTALL DIFFERENTIAL CASE SUB-ASSEMBLY


    1. A01JBII

      Install the differential case sub-assembly to the hybrid vehicle motor assembly.

  15. INSTALL THRUST NEEDLE ROLLER BEARING


    1. Apply ATF to the contact surfaces of the thrust needle roller bearing.

    2. A01JBPJE01
      Text in Illustration
      *1 Thrust Bearing Race
      *2 Thrust Needle Roller Bearing
      *3 No. 1 Thrust Bearing Race

      Install the No. 1 thrust bearing race, thrust needle roller bearing and thrust bearing race to the input shaft assembly.

  16. INSTALL INPUT SHAFT ASSEMBLY


    1. A01JCSA

      Install the input shaft assembly to the counter drive gear sub-assembly.

  17. INSTALL PLANETARY SUN GEAR


    1. A01JD03

      Install the planetary sun gear to the input shaft assembly.

    2. Select a planetary sun gear snap ring.


      1. A01JCM0E03
        Text in Illustration
        *a Straightedge
        *b Measured Area
        *c Dimension A

        Using a straightedge and vernier caliper, measure dimension A shown in the illustration.

        Dimension A
        Measured value - Straightedge thickness
      2. A01J9DRE02
        Text in Illustration
        *a Straightedge
        *b Measured Area
        *c Dimension B

        Using a straightedge and vernier caliper, measure dimension B shown in the illustration.

        Dimension B
        Measured value - Straightedge thickness

        Note

        Measure the dimensions without a planetary sun gear snap ring installed.

      3. A01JBJDE01
        Text in Illustration
        *a Dimension A
        *b Dimension B
        *c Dimension C

        Measure the dimension C.

        Dimension C
        Dimension A - Dimension B
      4. A01JASHE02
        Text in Illustration
        *a Straightedge
        *b Measured Area
        *c Dimension D

        Using a straightedge and vernier caliper, measure dimension D shown in the illustration.

        Dimension D
        Measured value - Straightedge thickness

      5. Select a planetary sun gear snap ring.

        Standard Value
        Planetary sun gear snap ring thickness = (Dimension D - Dimension C) - (0.1 to 0.2 mm (0.00394 to 0.00787 in.))

        Note

        There should be a clearance of 0.1 to 0.2 mm (0.00394 to 0.00787 in.) for the input shaft assembly. Therefore, use the above formula when selecting a planetary sun gear snap ring.

        <Planetary Sun Gear Snap Ring Thickness>
        Part No. Thickness (mm (in.)) Part No. Thickness (mm (in.))
        90520-31035 3.88 (0.153) 90520-31050 4.33 (0.170)
        90520-31036 3.91 (0.154) 90520-31051 4.36 (0.172)
        90520-31037 3.94 (0.155) 90520-31052 4.39 (0.173)
        90520-31038 3.97 (0.156) 90520-31053 4.42 (0.174)
        90520-31039 4.00 (0.157) 90520-31054 4.45 (0.175)
        90520-31040 4.03 (0.159) 90520-31055 4.48 (0.176)
        90520-31041 4.06 (0.160) 90520-31056 4.51 (0.178)
        90520-31042 4.09 (0.161) 90520-31057 4.54 (0.179)
        90520-31043 4.12 (0.162) 90520-31058 4.57 (0.180)
        90520-31044 4.15 (0.163) 90520-31059 4.60 (0.181)
        90520-31045 4.18 (0.165) 90520-31060 4.63 (0.182)
        90520-31046 4.21 (0.166) 90520-31061 4.66 (0.183)
        90520-31047 4.24 (0.167) 90520-31062 4.69 (0.185)
        90520-31048 4.27 (0.168) 90520-31063 4.72 (0.186)
        90520-31049 4.30 (0.169) - -
    3. A01JCY1

      Install the planetary sun gear snap ring to the input shaft assembly.

  18. INSTALL COUNTER DRIVEN GEAR SHIM


    1. Select a counter driven gear shim.


      1. A01JBNLE03
        Text in Illustration
        *a Straightedge
        *b Measured Area
        *c Dimension A

        Using a straightedge and vernier caliper, measure dimension A shown in the illustration.

        Dimension A
        Measured value - Straightedge thickness
      2. A01JCI6E02
        Text in Illustration
        *a Straightedge
        *b Measured Area
        *c Dimension B

        Using a straightedge and vernier caliper, measure dimension B shown in the illustration.

        Dimension B
        Measured value - Straightedge thickness

      3. Select a counter driven gear shim.

        Standard Value
        Counter driven gear shim thickness = (Dimension A - Dimension B) - (0 to 0.2 mm (0 to 0.00787 in.))

        Note

        There should be a clearance of 0 to 0.2 mm (0 to 0.00787 in.) for the counter driven gear sub-assembly. Therefore, use the above formula when selecting a counter driven gear shim.

        <Counter Driven Gear Shim Thickness>
        Part No. Thickness (mm (in.)) Part No. Thickness (mm (in.))
        90564-50281 2.00 (0.0787) 90564-50288 2.35 (0.0925)
        90564-50282 2.05 (0.0807) 90564-50289 2.40 (0.0945)
        90564-50283 2.10 (0.0827) 90564-50290 2.45 (0.0965)
        90564-50284 2.15 (0.0846) 90564-50291 2.50 (0.0984)
        90564-50285 2.20 (0.0866) 90564-50292 2.55 (0.100)
        90564-50286 2.25 (0.0886) 90564-50293 2.60 (0.102)
        90564-50287 2.30 (0.0906) - -
    2. A01JCD2

      Install the counter driven gear shim to the counter driven gear sub-assembly.

  19. INSTALL NO. 1 TRANSMISSION MAGNET


    1. A01JA2P

      Install the No. 1 transmission magnet to the hybrid vehicle motor assembly.

  20. INSTALL PARKING LOCK ROD SUB-ASSEMBLY


    1. A01JB5Q

      Align the slot with the protrusions on the No. 1 parking lock lever sub-assembly and install the parking lock rod sub-assembly.

  21. INSTALL NO. 1 PARKING LOCK SHAFT


    1. A01JBL9

      Install a new spacer to the No. 1 parking lock lever sub-assembly.

    2. A01J8RNE01
      Text in Illustration
      *1 No. 1 Parking Lock Lever Sub-assembly
      *2 Parking Lock Rod Sub-assembly

      Install the No. 1 parking lock lever sub-assembly and parking lock rod sub-assembly to the hybrid vehicle motor assembly.

    3. A01JCKI

      Install the No. 1 parking lock shaft to the hybrid vehicle motor assembly.

    4. A01J991E01
      Text in Illustration
      *1 Slotted Spring Pin
      *2 Spacer
      *3 No. 1 Parking Lock Shaft

      Using a 5 mm pin punch and hammer, drive in a new slotted spring pin to the No. 1 parking lock shaft.

    5. A01JAS6

      Turn the spacer as shown in the illustration.

    6. A01JAHFE01
      Text in Illustration
      *a Stake Point

      Using a 3 mm pin punch and hammer, stake the spacer.

      Note

      After staking the spacer, make sure that it is firmly secured.

  22. INSTALL RETAINER SPRING


    1. A01J9VLE01
      Text in Illustration
      *1 Retainer Spring
      *2 No. 1 Parking Lock Shaft
      *3 Hybrid Vehicle Motor Assembly

      Install the retainer spring to the hybrid vehicle motor assembly and No. 1 parking lock shaft.

      Note

      Check that the retainer spring is securely installed to the groove of the No. 1 parking lock shaft.

  23. INSTALL MANUAL DETENT SPRING SUB-ASSEMBLY


    1. A01JCQM

      Install the manual detent spring sub-assembly to the hybrid vehicle motor assembly with the bolt.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  24. INSTALL PARKING LOCK SLEEVE


    1. A01JAQ6

      Install the parking lock sleeve to the hybrid vehicle motor assembly.

  25. INSTALL TORSION SPRING


    1. A01J98P

      Install the parking lock pawl shaft and torsion spring to the hybrid vehicle motor assembly.

  26. INSTALL PAWL STOPPER PLATE


    1. A01J9EK

      Install the pawl stopper plate to the hybrid vehicle motor assembly with the 2 bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  27. INSTALL PARKING LOCK PAWL


    1. A01JAP7E01
      Text in Illustration
      *1 Torsion Spring
      *2 Pawl Stopper Plate
      *3 Parking Lock Pawl

      Install the parking lock pawl to the hybrid vehicle motor assembly with the parking lock pawl shaft.

      Note

      Make sure the torsion spring is attached to the parking lock pawl and pawl stopper plate.

  28. INSTALL INPUT SHAFT TYPE T OIL SEAL


    1. A01JBOWE01

      Using SST and hammer, install a new input shaft type T oil seal to the hybrid vehicle generator assembly.

      SST
      09950-60010   ( 09951-00340 )
      09950-70010   ( 09951-07150 )
      Standard Depth
      1.0 to 1.8 mm (0.0394 to 0.0709 in.)

      Note


      • Do not allow foreign matter to attach to the input shaft type T oil seal lip.

      • Do not install the input shaft type T oil seal at an angle.

    2. Coat the lip of the input shaft type T oil seal with a small amount of MP grease.

  29. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL (for RH Side)


    1. A01JAVBE01

      Using SST and hammer, install a new hybrid vehicle transaxle assembly type T oil seal to the hybrid vehicle generator assembly.

      SST
      09608-10010
      09950-70010   ( 09951-07150 )
      Standard Depth
      -0.5 to 0.5 mm (-0.0197 to 0.0197 in.)

      Note


      • Do not allow foreign matter to attach to the hybrid vehicle transaxle assembly type T oil seal lip.

      • Do not install the hybrid vehicle transaxle assembly type T oil seal at an angle.

    2. Coat the lip of the hybrid vehicle transaxle assembly type T oil seal with a small amount of MP grease.

  30. INSTALL TRANSAXLE HOUSING OIL SEPARATOR


    1. A01JD1X

      Install the transaxle housing oil separator to the hybrid vehicle generator assembly with the 2 bolts.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

  31. INSTALL HYBRID VEHICLE GENERATOR ASSEMBLY


    1. Clean the hybrid vehicle motor assembly installation surface of the hybrid vehicle generator assembly.

      Note


      • Do not allow any remaining seal packing to enter the hybrid vehicle generator assembly.

      • Do not damage the installation surface.

    2. Clean the hybrid vehicle generator assembly installation surface of the hybrid vehicle motor assembly.

      Note


      • Do not allow any remaining seal packing to enter the hybrid vehicle motor assembly.

      • Do not damage the installation surface.

    3. A01JCOX

      Apply seal packing to the hybrid vehicle motor assembly as shown in the illustration.

      Text in Illustration
      A01J8OW Seal Packing
      Seal Packing
      Toyota Genuine Seal Packing 1281, Three Bond 1281 or equivalent
      Standard Seal Diameter
      1.5 mm (0.0591 in.)

      Note


      • Clean the installation surfaces.

      • Check and clean the bolts and bolt holes.

      • Install the hybrid vehicle generator assembly within 3 minutes and tighten the bolts within 10 minutes of applying the seal packing.

      • Make sure to overlap the start and the end points of the seal packing.

      • Do not add fluid for at least 2 hours after installing the hybrid vehicle generator assembly.

      • Do not start the engine for at least 2 hours after installing the hybrid vehicle generator assembly.

    4. Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts and washer as shown in the illustration.

      A01J90EE01
      Text in Illustration
      *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger
      *3 Washer - -
      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Part Name Part No.
      No. 1 engine hanger 12281-37050
      No. 2 engine hanger 12282-37040
      Bolt 91552-81050

      Tech Tips

      When installing the No. 1 engine hanger, use a washer with an appropriate thickness so that the No. 1 engine hanger will not interfere with the installation surface of the transaxle housing.

    5. Using the sling device and chain block, install the hybrid vehicle generator assembly to the hybrid vehicle motor assembly.

      Note


      • Lift the hybrid vehicle generator assembly straight up.

      • Do not damage the input shaft type T oil seal with the input shaft assembly.

      • If it is difficult to install the hybrid vehicle generator assembly, turn the input shaft assembly left and right and engage the gears.

      • Do not directly hold the splines of the input shaft assembly with a tool when turning it.

    6. Remove the 2 bolts, washer, No. 1 engine hanger and No. 2 engine hanger from the hybrid vehicle generator assembly.

    7. A01J9VS

      Install the 8 bolts to the hybrid vehicle generator assembly.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

    8. Install the 2 bolts to the hybrid vehicle motor assembly.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }
    9. A01JAGX

      Install the 8 bolts to the hybrid vehicle generator assembly.

      Torque:
      29 N*m  { 300 kgf*cm, 22 ft.*lbf }

  32. INSTALL NO. 2 MOTOR WATER JACKET COVER ASSEMBLY


    1. Clean the No. 2 motor water jacket cover assembly installation surface of the hybrid vehicle transaxle assembly.

      Note

      Do not allow any remaining seal packing to enter the coolant path.

    2. A01J8TS

      Apply seal packing to the No. 2 motor water jacket cover assembly as shown in the illustration.

      Text in Illustration
      A01J8OW Seal Packing
      Seal Packing
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Standard Seal Diameter
      1.5 mm (0.0591 in.)

      Note


      • Clean and degrease the installation surface.

      • Clean and degrease the bolt and bolt holes.

      • Install the No. 2 motor water jacket cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying the seal packing.

      • Make sure to overlap the start and the end points of the seal packing.

      • Do not add coolant for at least 2 hours after installing the No. 2 motor water jacket cover assembly.

      • Do not turn the power switch on (READY) for at least 2 hours after installing the No. 2 motor water jacket cover assembly.

    3. A01JAEB

      Install the No. 2 motor water jacket cover assembly to the hybrid vehicle transaxle assembly with the 6 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  33. INSTALL NO. 1 MOTOR WATER JACKET COVER ASSEMBLY


    1. Clean the No. 1 motor water jacket cover assembly installation surface of the hybrid vehicle transaxle assembly.

      Note

      Do not allow any remaining seal packing to enter the coolant path.

    2. A01JBXL

      Apply seal packing to the No. 1 motor water jacket cover assembly as shown in the illustration.

      Text in Illustration
      A01J8OW Seal Packing
      Seal Packing
      Toyota Genuine Seal Packing 1282B, Three Bond 1282B or equivalent
      Standard Seal Diameter
      1.5 mm (0.0591 in.)

      Note


      • Clean and degrease the installation surface.

      • Clean and degrease the bolt and bolt holes.

      • Install the No. 1 motor water jacket cover assembly within 3 minutes and tighten the bolts within 10 minutes of applying the seal packing.

      • Make sure to overlap the start and the end points of the seal packing.

      • Do not add coolant for at least 2 hours after installing the No. 1 motor water jacket cover assembly.

      • Do not turn the power switch on (READY) for at least 2 hours after installing the No. 1 motor water jacket cover assembly.

    3. A01JAF7

      Install the No. 1 motor water jacket cover assembly to the hybrid vehicle transaxle assembly with the 6 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    4. A01JCEE

      Using a 10 mm hexagon socket wrench, install the drain plug and a new gasket to the No. 1 motor water jacket cover assembly.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  34. INSTALL DRAIN PLUG


    1. A01JBL0

      Using a 10 mm hexagon socket wrench, install the drain plug and a new gasket to the hybrid vehicle transaxle assembly.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  35. INSTALL FILLER PLUG


    1. A01JBQS

      Using a 10 mm hexagon socket wrench, install the filler plug and a new gasket to the hybrid vehicle transaxle assembly.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  36. INSTALL OIL PUMP DRIVE SHAFT


    1. A01JD3B

      Install the oil pump drive shaft to the hybrid vehicle transaxle assembly.

  37. INSTALL TRANSMISSION OIL PUMP COVER SUB-ASSEMBLY


    1. A01J9CK

      Coat a new O-ring with ATF and install it to the hybrid vehicle transaxle assembly.

      Note

      Be careful not to damage the O-ring.

    2. Apply ATF to the transaxle oil pump drive rotor and transmission oil pump driven rotor.

    3. A01JCDHE02
      Text in Illustration
      *1 Transaxle Oil Pump Drive Rotor
      *2 Transmission Oil Pump Driven Rotor
      *a Matchmark

      Install the transaxle oil pump drive rotor and transmission oil pump driven rotor to the hybrid vehicle transaxle assembly.

      Note


      • Align the matchmarks on the transmission oil pump drive rotor and the transmission oil pump driven rotor.

      • If the transaxle oil pump drive rotor or oil pump driven rotor has been replaced, inspect the fluid pressure of the transmission oil pump cover sub-assembly.

    4. A01JC6L

      Install the transmission oil pump cover sub-assembly to the hybrid vehicle transaxle assembly with the 4 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

      Note

      Make sure that the O-ring is not cut or pinched during installation.

    5. A01JCWY

      Coat a new O-ring with ATF and install it to the fluid pump cover plug.

    6. Install the fluid pump cover plug to the transmission oil pump cover sub-assembly.

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

  38. INSTALL WITH HEAD STRAIGHT SCREW PLUG


    1. Clean and degrease the bolt holes.

    2. A01JA1D

      Using a 6 mm hexagon socket wrench, install 2 new with head straight screw plugs to the hybrid vehicle transaxle assembly.

      Torque:
      18 N*m  { 180 kgf*cm, 13 ft.*lbf }

  39. INSTALL TRANSAXLE BREATHER PLUG


    1. A01JDBW

      Using a union nut wrench, install the transaxle breather plug to the hybrid vehicle transaxle assembly.

      Torque:
      11 N*m  { 115 kgf*cm, 8 ft.*lbf }

      Note

      Be careful not to damage the transaxle breather plug.

  40. INSTALL SHIFT CONTROL ACTUATOR ASSEMBLY


    1. A01JBQG

      Install the shift control actuator assembly to the hybrid vehicle transaxle assembly with 3 new shift control actuator bolts.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

      Tech Tips


      • Do not tap the shift control actuator assembly with a plastic hammer or similar tool when installing it.

      • As the position of the shift control actuator assembly is detected automatically, initialization is not necessary after disconnecting and reconnecting the cable to the auxiliary battery negative (-) terminal.

    2. A01JCHA

      Install 3 new shift control actuator bolt caps to the shift control actuator bolts.

      Note

      Push in each shift control actuator bolt cap firmly until the claw of the shift control actuator bolt cap engages with the shift control actuator bolt.

  41. INSTALL MOTOR CABLE


    1. A01J8DE

      Install the motor cable to the hybrid vehicle transaxle assembly with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note


      • Keep foreign matter, water, etc. away from the motor cable terminals and their installation area.

      • Insert the terminals straight in when installing the motor cable.

    2. A01J8L0

      Engage the 2 claws to install a new terminal cap to the hybrid vehicle transaxle assembly.

      Note


      • Keep foreign matter, water, etc. away from the terminal cap and its installation area.

      • Do not pinch the O-ring.

      • Check that the terminal cap is securely installed.

    3. A01JBI7

      Place the motor cable connector shell in position and install it with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  42. INSTALL GENERATOR CABLE


    1. A01JBDJ

      Install the generator cable to the hybrid vehicle transaxle assembly with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note


      • Keep foreign matter, water, etc. away from the generator cable terminals and their installation area.

      • Insert the terminals straight in when installing the generator cable.

    2. A01J9KJ

      Engage the 2 claws to install a new terminal cap to the hybrid vehicle transaxle assembly.

      Note


      • Keep foreign matter, water, etc. away from the terminal cap and its installation area.

      • Do not pinch the O-ring.

      • Check that the terminal cap is securely installed.

    3. A01J9II

      Place the generator cable connector shell in position and install it with the 3 bolts.

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

  43. INSPECT PARKING LOCK

    Note

    Confirm the safety of the working environment, then start the inspection.

    Tech Tips

    Perform this inspection on a level surface after installing the hybrid vehicle transaxle assembly to the vehicle.


    1. Turn the power switch on (IG).*1

    2. Depress the brake pedal and release the parking brake.*2

    3. Check that park (P) is selected.*3

    4. Push the vehicle forward by hand and check that it moves slightly and stops.*4

    5. Move the shift lever to neutral (N).*5

    6. Push the vehicle forward by hand and check that it moves.*6

    7. Press the P position switch and check that park (P) is selected.*7

    8. Push the vehicle forward by hand and check that it moves slightly and stops.*8

    9. Perform steps *3 to *8 again, pushing the vehicle rearward this time.