Installation
INSTALLATION
CAUTION / NOTICE / HINT
CAUTION:
The
engine assembly with hybrid vehicle transaxle assembly is very heavy.
Be sure to follow the procedure described in the repair manual, or the
engine lifter may suddenly drop.
PROCEDURE
1. INSTALL TRANSAXLE CASE PROTECTOR
(a) Install the transaxle case protector to the hybrid vehicle transaxle assembly with the clip.
(b) Install the 2 bolts.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
2. INSTALL STUD BOLT
(a) Using a E8 "TORX" socket wrench, install the 2 stud bolts to the hybrid vehicle transaxle assembly.
Torque:
30 N·m {306 kgf·cm, 22 ft·lbf}
3. INSTALL TRANSAXLE HOUSING PLUG
(a) Install the transaxle housing plug and a new gasket to the hybrid vehicle transaxle assembly.
Torque:
39.2 N·m {400 kgf·cm, 29 ft·lbf}
4. INSTALL WIRE HARNESS CLAMP BRACKET
(a) Install the 4 wire harness clamp brackets to the hybrid vehicle transaxle assembly with the 4 bolts.
Torque:
Bolt (A) :
20 N·m {204 kgf·cm, 15 ft·lbf}
Bolt (B) :
30 N·m {306 kgf·cm, 22 ft·lbf}
5. INSTALL TRANSMISSION WIRE
(a) Install the transmission wire to the hybrid vehicle transaxle assembly with the bolt.
Torque:
13 N·m {133 kgf·cm, 10 ft·lbf}
(b) Connect the connector.
6. INSTALL HOSE BRACKET
|
(a) Temporarily install the hose bracket to the hybrid vehicle transaxle assembly with the 2 bolts. |
|
(b) Tighten the 2 bolts in the order shown in the illustration.
Torque:
11.5 N·m {117 kgf·cm, 8 ft·lbf}
7. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET
(a) Install the No. 1 transmission control cable bracket to the hybrid vehicle transaxle assembly with the 2 bolts.
Torque:
12 N·m {122 kgf·cm, 9 ft·lbf}
8. INSTALL MOTOR COOLING COOLER
Click here 
9. INSTALL MOTOR CABLE
Click here
10. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY
| (a) Make sure that the knock pins are installed to the engine assembly. |
|
| (b)
Align the knock pins with the holes in the hybrid transaxle assembly
and, while keeping the contact surfaces of the engine assembly and
hybrid vehicle transaxle assembly in close contact with one another,
temporarily install the bolt (A).
NOTICE:
- When tightening the bolts, be sure that the contact surfaces of the
engine assembly and hybrid vehicle transaxle assembly are in close
contact with one another.
- Do not apply grease to the inner splines of the transmission input damper assembly or input shaft assembly.
- Make sure that the wire harness or similar items are not pinched between the contact surfaces.
- Do not use excessive force when installing the hybrid vehicle transaxle assembly.
- Make sure to align the hybrid vehicle transaxle assembly so that the
input shaft assembly of the hybrid vehicle transaxle assembly will be
inserted straight into the inner splines of the transmission input
damper assembly.
- When inserting the input shaft assembly of the hybrid vehicle transaxle
assembly into the inner splines of the transmission input damper
assembly, do not shake the hybrid vehicle transaxle assembly
excessively.
- When installing the hybrid vehicle transaxle assembly to the engine
assembly, make sure to securely fit the knock pins into the knock pin
holes.
| |
| (c)
While keeping the contact surfaces of the engine assembly and hybrid
vehicle transaxle assembly in close contact with one another, install
the 8 bolts. |
Bolt | Bolt Length |
Torque | | (A), (B) |
50 mm (1.97 in.) |
64 N*m (653 kgf*cm, 47 ft.*lbf) | |
(C) | 45 mm (1.77 in.) |
46 N*m (469 kgf*cm, 34 ft.*lbf) | |
(D) | 35 mm (1.38 in.) |
25 N*m (255 kgf*cm, 18 ft.*lbf) | |
|
11. INSTALL REAR ENGINE MOUNTING BRACKET
| (a) Install the rear engine mounting bracket to the hybrid vehicle transaxle assembly with the 4 bolts.
Torque: 42 N·m {428 kgf·cm, 31 ft·lbf} HINT: Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (A) → Fully tighten bolt (C) |
|
12. INSTALL REAR ENGINE MOUNTING INSULATOR
Click here
13. INSTALL FRONT ENGINE MOUNTING BRACKET
| (a) Install the front engine mounting bracket to the hybrid vehicle transaxle assembly with the 3 bolts.
Torque: 42 N·m {428 kgf·cm, 31 ft·lbf} HINT: Tightening order: Temporarily tighten bolt (A) → Fully tighten bolt (B) → Fully tighten bolt (C) → Fully tighten bolt (A) |
|
14. INSTALL FRONT ENGINE MOUNTING INSULATOR
(a) Install the front engine mounting insulator to the front engine mounting bracket with the bolt.
Torque:
72 N·m {734 kgf·cm, 53 ft·lbf}
15. INSTALL FRONT FRAME ASSEMBLY
Click here
16. INSTALL FLYWHEEL HOUSING SIDE COVER
(a) Install the flywheel housing side cover to the engine assembly.
17. INSTALL STARTER HOLE INSULATOR
(a) Install the starter hole insulator to the engine assembly with the 2 bolts.
Torque:
46 N·m {469 kgf·cm, 34 ft·lbf}
18. CONNECT HV AIR CONDITIONING WIRE
(a) Engage the guide to connect the HV air conditioning wire to the hybrid vehicle transaxle assembly.
(b) Install the bolt.
Torque:
20 N·m {204 kgf·cm, 15 ft·lbf}
19. CONNECT ENGINE WIRE
(a) Install the wire harness to the rack and pinion power steering gear assembly with the 2 bolts.
Torque:
10 N·m {102 kgf·cm, 7 ft·lbf}
(b) Connect the wire harness connector to the rack and pinion power steering gear assembly.
HINT:
Make sure that the connector is fully inserted before rotating the lock lever to engage the lock.
(c) Connect the 5 clamps.
(d) Install the 2 bolts.
Torque:
Bolt (A) :
20 N·m {204 kgf·cm, 15 ft·lbf}
Bolt (B) :
10 N·m {102 kgf·cm, 7 ft·lbf}
20. INSTALL STEERING GEAR HEAT INSULATOR
Click here
21. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
Click here
22. PERFORM RESOLVER LEARNING
NOTICE:
If the hybrid vehicle transaxle assembly has been replaced, make sure to perform resolver learning.
Click here
Removal
REMOVAL
CAUTION / NOTICE / HINT
The
necessary procedures (adjustment, calibration, initialization, or
registration) that must be performed after parts are removed and
installed, or replaced during hybrid vehicle transaxle assembly
removal/installation are shown below.
Necessary Procedures After Parts Removed/Installed/Replaced |
Replaced Part or Performed Procedure |
Necessary Procedure | Effect/Inoperative Function when Necessary Procedure not Performed |
Link |
|
*: When performing learning using the Techstream.
Click here  *1: The vehicle height changes because of suspension or tire replacement |
|
Auxiliary battery terminal is disconnected/reconnected |
Perform steering sensor zero point calibration |
Lane departure alert system (w/ Steering Control) |
|
|
Pre-collision system |
|
Intelligent clearance sonar system* |
|
Lighting system (w/ AFS)(EXT) |
|
Memorize steering angle neutral point |
Parking assist monitor system |
|
|
Panoramic view monitor system |
|
|
Replacement of ECM | Perform Vehicle Identification Number (VIN) registration |
MIL illuminates |
|
- Replacement of engine assembly
- Replacement of air fuel ratio sensor (sensor 2)
- Replacement of engine coolant temperature sensor
- Gas leak from exhaust system is repaired
| Inspection After Repair |
- Poor idle, etc.
- Engine start function, etc.
|
|
|
Replacement of inverter with converter assembly |
Resolver learning |
- DTCs are stored
- Slight vibration at a vehicle speed of 5 km/h (3 mph) or less
- Shock or vibration during acceleration
|
|
|
Replacement of hybrid vehicle transaxle assembly |
- Resolver learning
- Initialize resolver
|
| Front wheel alignment adjustment |
- Clear zero point calibration data.
- Perform yaw rate and acceleration sensor zero point calibration.
|
- DTCs are stored
- ABS warning light illuminates
- Brake warning light / yellow (minor malfunction) illuminates
- Slip indicator light illuminates
- VSC disabled or malfunctions
|
|
- Suspension, tires, etc.*1
- Replacement of front bumper assembly
|
- Measurement of ultrasonic sensor detection angle
- Ultrasonic sensor detection angle registration
|
- Intelligent clearance sonar system
- Intuitive parking assist system
|
|
|
Suspension, tires, etc.*1 |
Rear television camera assembly optical axis (Back camera position setting) |
Parking assist monitor system |
for Initialization
for Calibration |
|
Replacement of front bumper assembly |
Front television camera view adjustment |
Panoramic view monitor system |
for Initialization
for Calibration |
|
Suspension, tires, etc.*1 |
- Parking assist ECU initialization
- Adjust steering angle
- Television camera assembly optical axis adjustment (Back camera position setting)
|
- Replacement of headlight ECU sub-assembly LH
- Replacement of headlight assembly LH
| Synchronize the vehicle information |
Lighting system (for HV Model with Cornering Light) |
|
CAUTION:
- Orange wire harnesses and connectors indicate high-voltage circuits. To
prevent electric shock, always follow the procedure described in the
repair manual.
Click here
- To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.
- To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.
- To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.
- The engine assembly with transaxle is very heavy. Be sure to follow the
procedure described in the repair manual, or the engine lifter may
suddenly drop or the engine assembly with transaxle may fall off the
engine lifter.
|
*a |
An Object Exceeding Weight Limit of Engine Lifter |
- The hybrid vehicle transaxle assembly is very heavy. Be sure to follow
the procedure described in the repair manual, or the transmission jack
may suddenly drop or a part may fall.
|
*a |
Object Exceeding Weight Limit of Transmission Jack |
NOTICE:
- After turning the power switch off, waiting time may be required before
disconnecting the cable from the negative (-) auxiliary battery
terminal. Therefore, make sure to read the disconnecting the cable from
the negative (-) auxiliary battery terminal notices before proceeding
with work.
Click here
- If the ECM has been struck or dropped, replace it.
- Perform Vehicle Identification Number (VIN) registration when replacing the ECM.
Click here
PROCEDURE
1. PERFORM RESOLVER INITIALIZATION
NOTICE:
If
it is necessary to replace the hybrid vehicle transaxle assembly, make
sure to perform resolver initialization before starting work.
Click here
2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
Click here
3. REMOVE FUEL DELIVERY GUARD
Click here
4. INSTALL ENGINE HANGERS
Click here
5. REMOVE STEERING GEAR HEAT INSULATOR
Click here
6. DISCONNECT ENGINE WIRE
(a) Remove the 2 bolts.
(b) Disconnect the 5 clamps.
(c) Disconnect the wire harness connector from the rack and pinion power steering gear assembly.
HINT:
Release the lock before rotating the lock lever.
(d) Remove the 2 bolts and separate the wire harness from the rack and pinion power steering gear assembly.
7. DISCONNECT HV AIR CONDITIONING WIRE
(b) Disengage the guide to disconnect the HV air conditioning wire from the hybrid vehicle transaxle assembly.
8. REMOVE STARTER HOLE INSULATOR
| (a) Remove the 2 bolts and starter hole insulator from the engine assembly. |
|
9. REMOVE FLYWHEEL HOUSING SIDE COVER
| (a) Remove the flywheel housing side cover from the engine assembly. |
|
10. REMOVE FRONT FRAME ASSEMBLY
Click here
11. REMOVE FRONT ENGINE MOUNTING INSULATOR
| (a) Remove the bolt and front engine mounting insulator from the front engine mounting bracket. |
|
12. REMOVE FRONT ENGINE MOUNTING BRACKET
| (a) Remove the 3 bolts and front engine mounting bracket from the hybrid vehicle transaxle assembly. |
|
13. REMOVE REAR ENGINE MOUNTING INSULATOR
Click here
14. REMOVE REAR ENGINE MOUNTING BRACKET
| (a) Remove the 4 bolts and rear engine mounting bracket from the hybrid vehicle transaxle assembly. |
|
15. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY
| (a) Remove the 8 bolts and hybrid vehicle transaxle assembly from the engine assembly.
NOTICE:
- To avoid damaging the knock pins, do not pry between the hybrid vehicle transaxle assembly and engine assembly.
- To prevent the splines of the transmission input damper assembly from
becoming misaligned, do not allow the hybrid vehicle transaxle assembly
to hit the transmission input damper assembly during hybrid vehicle
transaxle assembly removal and installation.
| |
16. REMOVE MOTOR CABLE
Click here
17. REMOVE MOTOR COOLING COOLER
Click here
18. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET
| (a) Remove the 2 bolts and No. 1 transmission control cable bracket from the hybrid vehicle transaxle assembly. |
|
19. REMOVE HOSE BRACKET
|
(a) Remove the 2 bolts and hose bracket from the hybrid vehicle transaxle assembly. |
|
20. REMOVE TRANSMISSION WIRE
| (a) Disconnect the connector. | |
(b) Remove the bolt and transmission wire from the hybrid vehicle transaxle assembly.
21. REMOVE WIRE HARNESS CLAMP BRACKET
(a) Remove the 4 bolts and 4 wire harness clamp brackets from the hybrid vehicle transaxle assembly.
22. REMOVE TRANSAXLE HOUSING PLUG
| (a) Remove the transaxle housing plug and gasket from the hybrid vehicle transaxle assembly. |
|
23. REMOVE STUD BOLT
| (a) Using a E8 "TORX" socket wrench, remove the 2 stud bolts from the hybrid vehicle transaxle assembly. |
|
24. REMOVE TRANSAXLE CASE PROTECTOR
(b) Remove the clip and transaxle case protector from the hybrid vehicle transaxle assembly.
