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Hybrid Vehicle Transaxle ASSY: Replacement

NOTE:
  • When working on the high voltage systems, always wear insulated gloves.
  • After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU.
  • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
  • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.
  1. DISCONNECT BATTERY NEGATIVE TERMINAL 
  2. REMOVE SERVICE PLUG GRIP (SEE  SERVICE PLUG GRIP  ) 
  3. REMOVE FRONT WHEELS 
  4. REMOVE ENGINE UNDER COVER LH 
  5. REMOVE ENGINE UNDER COVER RH 
  6. DRAIN COOLANT (SEE  REPLACEMENT   ) 
  7. DRAIN TRANSAXLE OIL (SEE  ON-VEHICLE INSPECTION   ) 
  8. REMOVE HOOD SUB-ASSY (SEE  HOOD  ) 
  9. REMOVE FR WIPER ARM RH (SEE  WIPER & WASHER  ) 
  10. REMOVE FR WIPER ARM LH (SEE  WIPER & WASHER  ) 
  11. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (SEE  HYBRID CONTROL SYSTEM W/CONVERTER INVERTER ASSY  ) 
  12. REMOVE W/CONVERTER INVERTER ASSY (SEE  HYBRID CONTROL SYSTEM W/CONVERTER INVERTER ASSY  ) 
  13. REMOVE AIR CLEANER ASSY (SEE  REPLACEMENT  ) 
  14. DISCONNECT WIRE HARNESS 
    1. Disconnect the 3 connectors shown in the illustration and the clamp.
      Fig 1: Disconnecting Clamp
      G02920918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the 2 clamps shown in the illustration.
      Fig 2: Separating Clamp
      G02920919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the connector.
    4. Remove the 3 bolts and the transmission case cover from the hybrid vehicle transaxle.
      Fig 3: Removing Transmission Case Cover
      G02920920Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the 2 clamps.
      Fig 4: Disconnecting Clamp
      G02920921Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the bolt and the earth wire.
    Fig 5: Removing Bolt And Earth Wire
    G02920922Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. SEPARATE INVERTER COOLING HOSE NO.4 
    1. Remove the 4 clamps and disconnect the 3 hoses.
    Fig 6: Disconnecting Clamps And Hoses
    G02920923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FRONT DRIVE SHAFT ASSY LH (SEE  AXLE SHAFTS  ) 
  17. REMOVE FRONT DRIVE SHAFT ASSY RH (SEE  AXLE SHAFTS  ) 
    1. SST 09520-01010, 09520-24010 (09520-32040)
  18. SEPARATE EXHAUST PIPE ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  19. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSY (SEE  REPLACEMENT  ) 
  20. SUSPEND ENGINE ASSY 
    1. Disconnect the 2 PCV hoses.
    2. Install the No.1 and No.2 engine hangers in the correct direction.
      1. Parts No.: 
      2. No.1 engine hanger: 12281-22021 
      3. No.2 engine hanger: 12281-15040 
      4. Bolt: 91512-B1016 
      5. Torque: 38 N.m (387 kgf.cm, 28 ft.lbf) 
    3. Attach the engine chain hoist to the engine hangers.
    CAUTION: Do not attempt to hang the engine by hooking the chain to any other parts.
    Fig 7: Installing No. 1 And 2 Engine Hangers
    G02920924Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. SUPPORT HYBRID VEHICLE TRANSAXLE ASSY 
    1. Using a transmission jack, support the hybrid vehicle transaxle assy.
  22. SEPARATE ENGINE MOUNTING BRACKET NO.3 
    1. Remove the nut and disconnect engine mounting bracket No.3 from the engine mounting insulator.
    Fig 8: Disconnecting Engine Mounting Bracket No-3
    G02920925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE HYBRID VEHICLE TRANSAXLE ASSY 
    1. Remove the 2 bolts, starter cover and housing side cover.
      Fig 9: Removing Starter Cover And Housing Side Cover
      G02920926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 bolts and hybrid vehicle transaxle assy.
    NOTE: To avoid damage to the knock pin, do not pry the connecting portion of the HV transaxle assy and the engine.
    Fig 10: Removing Hybrid Vehicle Transaxle Assy
    G02920927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE INVERTER COOLING HOSE NO.6 
    1. Remove the clamp and inverter cooling hose No.6.
    Fig 11: Locating Clamp And Inverter Cooling Hose No.6.
    G02920928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE ENGINE MOUNTING BRACKET NO.3 
    1. Remove the 3 bolts and engine mounting bracket No.3.
      Fig 12: Removing Engine Mounting Bracket No-3
      G02920929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 bolts and stay shown in the illustration.
    Fig 13: Removing Stay
    G02920930Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. INSTALL ENGINE MOUNTING BRACKET NO.3 
    1. Install the stay in the position shown in the illustration using bolts.
      1. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 
      Fig 14: Installing Stay
      G02920931Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install engine mounting bracket No.3 using 3 bolts.
      1. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 
    Fig 15: Installing Engine Mounting Bracket No-3
    G02920932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL INVERTER COOLING HOSE NO.6 
    1. Connect the inverter cooling hose No.6 and install the clamp.
    Fig 16: Connecting Inverter Cooling Hose No-6 And Clamp
    G02920933Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL HYBRID VEHICLE TRANSAXLE ASSY 
    1. Install the hybrid vehicle transaxle assy with 6 bolts.
      1. Torque: 33 N.m (337 kgf.cm, 24 ft.lbf) 
      NOTE:
      • Ensure that the knock pin is installed on the engine side.
      • Tighten the 6 bolts in the positions shown in the illustration by placing the HV transaxle assy in a horizontal position and aligning the knock pin and its hole.
      Fig 17: Installing Hybrid Transaxle Assy
      G02920934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the housing side cover and starter cover with the 2 bolts.
      1. Torque: 32 N.m (326 kgf.cm, 23 ft.lbf) 
    Fig 18: Installing Housing Side Cover And Starter Cover
    G02920935Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. CONNECT ENGINE MOUNTING BRACKET NO.3 
    1. Connect the engine mounting bracket No.3 to the engine mounting insulator using a nut.
      1. Torque: 80 N.m (816 kgf.cm, 59 ft.lbf) 
    Fig 19: Connecting Engine Mounting Bracket No-3
    G02920936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE ENGINE HANGER NO.1 
    1. Remove the bolt and engine hanger.
  31. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY (SEE  REPLACEMENT  ) 
    1. SST 09670-00010
  32. CONNECT EXHAUST PIPE ASSY (SEE  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  33. INSTALL FRONT DRIVE SHAFT ASSY LH (SEE  AXLE SHAFTS  ) 
  34. INSTALL FRONT DRIVE SHAFT ASSY RH (SEE  AXLE SHAFTS  ) 
  35. CONNECT INVERTER COOLING HOSE NO.4 
    1. Connect the 3 hoses with the 4 clamps.
    Fig 20: Connecting 3 Hoses With 4 Clamps
    G02920937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. CONNECT CONNECTOR 
    1. Connect the earth wire using a bolt.
      1. Torque: 9.0 N.m (92 kgf.cm, 80 in.lbf) 
      Fig 21: Connecting Earth Wire
      G02920938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 clamps.
      Fig 22: Connecting 2 Clamps
      G02920939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the transmission case cover to the hybrid vehicle transaxle using the 3 bolts.
      1. Torque: 7.0 N.m (71 kgf.cm, 62 in.lbf) 
    4. Connect the connector.
      Fig 23: Installing Transmission Case Cover
      G02920940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Connect the clamps in the 2 locations shown in the illustration.
      Fig 24: Connecting Clamps
      G02920941Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the clamp and the 3 connectors shown in the illustration.
    Fig 25: Connecting Clamp And 3 Connectors
    G02920942Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. INSTALL AIR CLEANER ASSY (SEE  REPLACEMENT  ) 
  38. INSTALL W/CONVERTER INVERTER ASSY (SEE  HYBRID CONTROL SYSTEM W/CONVERTER INVERTER ASSY  ) 
  39. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT (SEE  HYBRID CONTROL SYSTEM W/CONVERTER INVERTER ASSY  ) 
  40. INSTALL FR WIPER ARM LH (SEE  WIPER & WASHER  ) 
  41. INSTALL FR WIPER ARM RH (SEE  WIPER & WASHER  ) 
  42. INSTALL HOOD SUB-ASSY (SEE  HOOD  ) 
  43. INSPECT HOOD SUB-ASSY (SEE  HOOD  ) 
  44. ADJUST HOOD SUB-ASSY (SEE  HOOD  ) 
  45. INSTALL ENGINE UNDER COVER RH 
  46. INSTALL ENGINE UNDER COVER LH 
  47. INSTALL FRONT WHEELS 
  48. INSTALL SERVICE PLUG GRIP (SEE  SERVICE PLUG GRIP  ) 
  49. CONNECT BATTERY NEGATIVE TERMINAL 
  50. ADD TRANSAXLE OIL 

    Fluid type: AUTO FLUID WS 

    Capacity: 3.8 liters (4.0 US qts, 3.3 lmp. qts) 

  51. INSPECT TRANSAXLE OIL (SEE  ON-VEHICLE INSPECTION   ) 
  52. ADD COOLANT (SEE  REPLACEMENT   ) 
  53. CHECK FOR ENGINE COOLANT LEAKS (SEE  INSPECTION  ) 
  54. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (SEE  SPECIFICATIONS & PROCEDURES  ) 
  55. DELETE TORQUE ZERO POINT (SEE  ELECTRIC POWER STEERING SYSTEM - DIAGNOSIS  ) 
  56. PERFORM INITIALIZATION (SEE  INTRODUCTION  ) 
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