HYBRID VEHICLE TRANSAXLE INSTALLATION
PROCEDURE
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INSTALL MOTOR CABLE BRACKET
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Install the motor cable bracket to the hybrid vehicle transaxle assembly with the bolt.
- Torque:
- 23 N*m { 235 kgf*cm, 17 ft.*lbf }
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INSTALL WIRE HARNESS CLAMP BRACKET
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Install the 2 wire harness clamp brackets to the hybrid vehicle transaxle assembly with the 2 bolts.
- Torque:
- Bolt A
- 29 N*m { 296 kgf*cm, 21 ft.*lbf }
- Bolt B
- 23 N*m { 235 kgf*cm, 17 ft.*lbf }
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INSTALL MOTOR CABLE
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INSTALL GENERATOR CABLE
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INSTALL REAR ENGINE MOUNTING BRACKET
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Install the rear engine mounting bracket with the 4 bolts in several steps.
- Torque:
- 45 N*m { 459 kgf*cm, 33 ft.*lbf }
Note
Temporarily tighten bolt A, and then fully tighten the 4 bolts in the order of C, B, D and A.
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INSTALL FRONT ENGINE MOUNTING BRACKET
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Install the front engine mounting bracket with the 3 bolts in several steps.
- Torque:
- 64 N*m { 653 kgf*cm, 47 ft.*lbf }
Note
Temporarily tighten bolt A, and then fully tighten the 3 bolts in the order of B, C and A.
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SUPPORT HYBRID VEHICLE TRANSAXLE ASSEMBLY
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Support the hybrid vehicle transaxle assembly with a transmission jack.
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INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY
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Text in Illustration *1 Knock Pin Make sure that the knock pins are installed to the engine.
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Using an transmission jack, align the engine assembly and hybrid vehicle transaxle assembly, fit the knock pins into the knock pin holes, and tighten the 7 bolts shown in the illustration.
- Torque:
- 33 N*m { 337 kgf*cm, 24 ft.*lbf }
Note
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Make sure to align the hybrid vehicle transaxle assembly so that the input shaft of the hybrid vehicle transaxle assembly will be inserted straight into the inner splines of the transmission input damper.
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When inserting the input shaft of the hybrid vehicle transaxle assembly into the inner splines of the transmission input damper, do not shake the hybrid vehicle transaxle excessively.
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When mounting the hybrid vehicle transaxle assembly to the engine, make sure to securely fit the knock pins into the knock holes.
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Push in the hybrid vehicle transaxle assembly so that the contact surfaces of the engine and the hybrid vehicle transaxle assembly are aligned evenly.
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While mounting the hybrid vehicle transaxle assembly to the engine assembly, temporarily tighten the bolt (A), and then fully tighten the 3 bolts in the order of B, A and C.
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Do not hang the hybrid vehicle transaxle assembly off of the engine if the contact surfaces of the engine and the hybrid vehicle transaxle assembly are not in full contact. The knock holes of the hybrid vehicle transaxle case may be deformed due to the excessive weight of the engine and hybrid vehicle transaxle assembly, resulting in misalignment between the engine and hybrid vehicle transaxle assembly.
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INSTALL ENGINE MOUNTING BRACKET LH
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Install the engine mounting bracket LH with 3 new bolts in several steps.
- Torque:
- 64 N*m { 653 kgf*cm, 47 ft.*lbf }
Note
Temporarily tighten bolt A, and then fully tighten the 3 bolts in the order of B, C and A.
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Install the engine mounting insulator LH with the bolt and nut.
- Torque:
- 56 N*m { 571 kgf*cm, 41 ft.*lbf }
Note
When installing the engine mounting insulator, tighten the nut while holding the bolt.
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INSTALL REAR ENGINE MOUNTING INSULATOR
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INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
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INSTALL FRONT ENGINE MOUNTING INSULATOR
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INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY
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Install the front crossmember to the body with the 4 bolts.
- Torque:
- 96 N*m { 979 kgf*cm, 71 ft.*lbf }
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Install the front engine mounting insulator to the front crossmember with the 2 bolts.
- Torque:
- 95 N*m { 969 kgf*cm, 70 ft.*lbf }
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Tighten the front engine mounting insulator with the bolt and nut.
- Torque:
- 145 N*m { 1479 kgf*cm, 107 ft.*lbf }
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INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH
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INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH
Tech Tips
Perform the same procedure as for the LH side.
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INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH
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INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH
Tech Tips
Perform the same procedure as for the LH side.
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INSTALL FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT
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INSTALL FLYWHEEL HOUSING SIDE COVER
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Install the flywheel housing side cover.
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INSTALL STARTER HOLE INSULATOR
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Install the starter hole insulator with the 2 bolts.
- Torque:
- 37 N*m { 377 kgf*cm, 27 ft.*lbf }
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REMOVE ENGINE HANGERS
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Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.
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INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH
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INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH
Tech Tips
Perform the same procedure as for the LH side.
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INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
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INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
Tech Tips
Perform the same procedure as for the LH side.
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CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH
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CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH
Tech Tips
Perform the same procedure as for the LH side.
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INSTALL FRONT STABILIZER LINK ASSEMBLY LH
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INSTALL FRONT STABILIZER LINK ASSEMBLY RH
Tech Tips
Perform the same procedure as for the LH side.
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CONNECT TIE ROD END SUB-ASSEMBLY LH
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CONNECT TIE ROD END SUB-ASSEMBLY RH
Tech Tips
Perform the same procedure as for the LH side.
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INSTALL FRONT SPEED SENSOR LH
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INSTALL FRONT SPEED SENSOR RH
Tech Tips
Perform the same procedure as for the LH side.
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INSTALL FRONT AXLE SHAFT NUT LH
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INSTALL FRONT AXLE SHAFT NUT RH
Tech Tips
Perform the same procedure as for the LH side.
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INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/ Exhaust Heat Recirculation System)
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INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/o Exhaust Heat Recirculation System)
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INSTALL FRONT CENTER FLOOR BRACE
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INSTALL FRONT NO. 3 ENGINE UNDER COVER
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CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
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CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for LHD)
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CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for RHD)
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ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
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INSTALL COLUMN HOLE COVER SILENCER SHEET (for LHD)
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INSTALL COLUMN HOLE COVER SILENCER SHEET (for RHD)
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INSTALL WIRE HARNESS
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Connect the 12 wire harness clamps and 6 connectors and install the 2 bolts.
- Torque:
- 8.4 N*m { 85 kgf*cm, 74 in.*lbf }
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Connect the wire harness with the clamp.
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Text in Illustration *a Green-colored Lock Connect the connector and lock the green-colored lock as shown in the illustration.
CAUTION:
Wear insulated gloves when performing the procedure.
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Install the earth wire with the bolt.
- Torque:
- 8.4 N*m { 85 kgf*cm, 74 in.*lbf }
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Connect the wire harness 2 clamps to the engine room junction block.
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Connect the 2 connectors to the engine room junction block.
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Connect the connector to the ECM with the lock lever.
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Connect the 2 clamps.
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INSTALL WATER HOSE
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Install the water hose to the hybrid vehicle transaxle assembly with the 2 hose clamps.
Text in Illustration *1 Water Hose *2 No. 2 Motor Water Jacket Cover Assembly *3 Hose Clamp *a 2 to 7 mm (0.0787 to 0.276 in.) *b Alignment Mark *c Yellow Mark *d Within 45° of the center of the clamp claw *e Green Mark *f Downward Note
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Align the yellow mark of the water hose and the alignment mark of the No. 2 motor water jacket cover assembly.
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Install the water hose upper clamp so that the center of the clamp claws is within 45° of the center of the matchmark of the No. 2 motor water jacket cover assembly as shown in the illustration.
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Install the water hose so that the green mark of the water hose is within 15° of facing downward.
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Connect the clamp to the wire harness clamp bracket.
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CONNECT NO. 5 INVERTER COOLING HOSE
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CONNECT NO. 3 INVERTER COOLING HOSE
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INSTALL RADIATOR PIPE
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CONNECT NO. 4 WATER BY-PASS HOSE
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CONNECT NO. 1 RADIATOR HOSE
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INSTALL INVERTER TRAY BRACKET
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INSTALL INVERTER RESERVE TANK ASSEMBLY
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INSTALL INVERTER WITH CONVERTER ASSEMBLY
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CONNECT WATER HOSE
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CONNECT NO. 2 ENGINE ROOM WIRE
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REMOVE INVERTER COVER
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CONNECT NO. 2 ENGINE WIRE
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CONNECT MOTOR CABLE
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CONNECT GENERATOR CABLE
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CONNECT FRAME WIRE
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CHECK HIGH VOLTAGE CABLE CONNECTION
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INSTALL INVERTER COVER
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INSTALL ENGINE ROOM MAIN WIRE
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INSTALL NO. 1 INVERTER BRACKET
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INSTALL AIR CLEANER HOSE ASSEMBLY
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INSTALL AIR CLEANER CASE
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INSTALL INLET AIR CLEANER ASSEMBLY
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INSTALL AIR CLEANER CAP SUB-ASSEMBLY
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INSTALL SERVICE PLUG GRIP
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INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)
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INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)
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INSTALL COWL BODY MOUNTING REINFORCEMENT LH (for LHD)
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INSTALL COWL BODY MOUNTING REINFORCEMENT RH (for RHD)
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INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
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ADD HYBRID TRANSAXLE FLUID
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ADD COOLANT (for Inverter)
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ADD COOLANT (for Engine)
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INSPECT HYBRID TRANSAXLE FLUID
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INSPECT FOR HYBRID TRANSAXLE FLUID LEAK
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INSPECT FOR COOLANT LEAK (for Inverter)
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INSPECT FOR COOLANT LEAK (for Engine)
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INSPECT FOR EXHAUST GAS LEAK
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INSTALL NO. 1 ENGINE UNDER COVER
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INSTALL NO. 2 ENGINE UNDER COVER
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INSTALL FRONT LOWER BUMPER ABSORBER
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INSTALL REAR ENGINE UNDER COVER LH
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INSTALL REAR ENGINE UNDER COVER RH
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INSTALL FRONT WHEELS
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INSTALL HOOD SUB-ASSEMBLY
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Install the hood sub-assembly to the hood hinge assembly RH and hood hinge assembly LH with the 4 bolts.
- Torque:
- 13 N*m { 133 kgf*cm, 10 ft.*lbf }
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Connect the clamp and washer hose.
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INSPECT HOOD SUB-ASSEMBLY
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ADJUST HOOD SUB-ASSEMBLY
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INSTALL RADIATOR SUPPORT OPENING COVER
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INSTALL NO. 2 CYLINDER HEAD COVER
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INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
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CHECK ABS SPEED SENSOR SIGNAL