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Home >> Toyota >> 2012 >> Prius V L4-1.8L (2ZR-FXE) Hybrid >> Repair and Diagnosis >> Transmission and Drivetrain >> Continuously Variable Transmission/Transaxle >> Service and Repair >> Removal and Replacement >> Hybrid Vehicle Transaxle >> Installation

Installation





P410 HYBRID TRANSMISSION / TRANSAXLE: HYBRID VEHICLE TRANSAXLE: INSTALLATION

1. INSTALL MOTOR CABLE BRACKET

(a) Install the motor cable bracket with the bolt.

Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)

2. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the 2 wire harness clamp brackets with the 2 bolts.





Bolt A - Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

Bolt B - Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)

3. INSTALL REAR ENGINE MOUNTING BRACKET

(a) Install the rear engine mounting bracket with the 4 bolts in several steps.





Torque : 45 Nm (459 kgf-cm, 33 ft-lbf)

NOTICE:
Temporarily tighten bolt A, and then fully tighten the 4 bolts in the order of C, B, D and A.

4. INSTALL FRONT ENGINE MOUNTING BRACKET

(a) Install the front engine mounting bracket with the 3 bolts in several steps.





Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

NOTICE:
Temporarily tighten bolt A, and then fully tighten the 3 bolts in the order of B, C and A.

5. SUPPORT HYBRID VEHICLE TRANSAXLE ASSEMBLY

(a) Support the hybrid vehicle transaxle assembly with a transmission jack.

6. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY

(a) Make sure that the knock pins are installed to the engine.





Text in Illustration





(b) 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 Nm (337 kgf-cm, 24 ft-lbf)

NOTICE:
* Make sure to align the hybrid vehicle transaxle so that the input shaft of the hybrid vehicle transaxle will be inserted straight into the inner splines of the transmission input damper.
* When inserting the input shaft of the hybrid vehicle transaxle into the inner splines of the transmission input damper, do not shake the hybrid vehicle transaxle excessively.
* When mounting the hybrid vehicle transaxle to the engine, make sure to securely fit the knock pins into the knock holes.
* Push in the hybrid vehicle transaxle so that the contact surfaces of the engine and the hybrid vehicle transaxle are aligned evenly.
* While mounting the hybrid vehicle transaxle to the engine, temporarily tighten the bolt (A), fully tighten the bolt (B), fully tighten the bolt (A), and then fully tighten the bolts (C).
* Do not hang the hybrid vehicle transaxle off of the engine if the contact surfaces of the engine and the hybrid vehicle transaxle 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, resulting in misalignment between the engine and hybrid vehicle transaxle.

7. INSTALL ENGINE MOUNTING BRACKET LH

(a) Install the engine mounting bracket LH with 3 new bolts in several steps.





Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

NOTICE:
Temporarily tighten bolt A, and then fully tighten the 3 bolts in the order of B, C and A.

(b) Install the engine mounting insulator LH with the through bolt and nut.

Torque : 56 Nm (571 kgf-cm, 41 ft-lbf)

NOTICE:
When installing the engine mounting insulator, tighten the nut while holding the bolt.

8. INSTALL REAR ENGINE MOUNTING INSULATOR Installation

9. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Installation

10. INSTALL FRONT ENGINE MOUNTING INSULATOR Installation

11. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY

(a) Install the front crossmember with the 4 bolts.

Torque : 96 Nm (979 kgf-cm, 71 ft-lbf)

(b) Install the front engine mounting insulator to the front crossmember with the 2 bolts.

Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

(c) Tighten the front engine mounting insulator with the bolt and nut.

Torque : 145 Nm (1479 kgf-cm, 107 ft-lbf)

12. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH Installation

13. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

HINT
Perform the same procedure as for the LH side.

14. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH Installation

15. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

16. INSTALL FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT Installation

17. INSTALL FLYWHEEL HOUSING SIDE COVER

(a) Install the flywheel housing side cover.

18. INSTALL STARTER HOLE INSULATOR

(a) Install the starter hole insulator with the 2 bolts.

Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)

19. REMOVE ENGINE HANGERS

(a) Remove the 2 bolts and 2 engine hangers.

20. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH Installation

21. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH

HINT
Perform the same procedure as for the LH side.

22. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

23. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

24. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH Installation

25. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

26. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

27. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

28. CONNECT TIE ROD END SUB-ASSEMBLY LH Installation

29. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

30. INSTALL FRONT SPEED SENSOR LH Installation

31. INSTALL FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

32. INSTALL FRONT AXLE SHAFT NUT LH Installation

33. INSTALL FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

34. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

35. INSTALL FRONT CENTER FLOOR BRACE Installation

36. INSTALL FRONT NO. 3 ENGINE UNDER COVER Installation

37. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation

38. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

39. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

40. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation

41. INSTALL WIRE HARNESS

(a) Connect the 12 wire harness clamps and 6 connectors and install the 2 bolts.

Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)

(b) Connect the wire harness with the clamp.

(c) Connect the connector and lock the green-colored lock as shown in the illustration.





CAUTION:
Wear insulated gloves when performing the procedure.

Text in Illustration





(d) Install the earth wire with the bolt.

Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)

(e) Connect the wire harness 2 clamps to the engine room junction block.

(f) Connect the 2 connectors to the engine room junction block.

(g) Connect the connector to the ECM with the lock lever.

(h) Connect the 2 clamps.

42. INSTALL WATER HOSE

(a) Install the water hose with the 2 clamps.





Text in Illustration





NOTICE:
* Align the yellow mark of the water hose and the alignment mark of the No. 2 motor water jacket cover assembly.
* 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.
* Install the water hose so that the green mark of the water hose is within 15° of facing downward.

(b) Connect the clamp.

43. CONNECT NO. 5 INVERTER COOLING HOSE Installation

44. CONNECT NO. 3 INVERTER COOLING HOSE Installation

45. INSTALL RADIATOR PIPE Installation

46. CONNECT NO. 4 WATER BY-PASS HOSE Installation

47. CONNECT NO. 1 RADIATOR HOSE Installation

48. INSTALL INVERTER TRAY BRACKET Installation

49. INSTALL INVERTER RESERVE TANK ASSEMBLY Installation

50. INSTALL INVERTER WITH CONVERTER ASSEMBLY Installation

51. CONNECT WATER HOSE Installation

52. CONNECT NO. 2 ENGINE ROOM WIRE Installation

53. REMOVE INVERTER COVER Installation

54. CONNECT NO. 2 ENGINE WIRE Installation

55. CONNECT MOTOR CABLE Installation

56. CONNECT GENERATOR CABLE Installation

57. CONNECT FRAME WIRE Installation

58. CHECK HIGH VOLTAGE CABLE CONNECTION Installation

59. INSTALL INVERTER COVER Installation

60. INSTALL ENGINE ROOM MAIN WIRE Installation

61. INSTALL NO. 1 INVERTER BRACKET Installation

62. INSTALL AIR CLEANER HOSE ASSEMBLY Installation

63. INSTALL AIR CLEANER CASE Installation

64. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

65. INSTALL INLET AIR CLEANER ASSEMBLY Installation

66. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

67. INSTALL SERVICE PLUG GRIP

Installation

68. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

69. INSTALL COWL BODY MOUNTING REINFORCEMENT LH Installation

70. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Installation

71. ADD HYBRID TRANSAXLE FLUID Adjustments

72. ADD COOLANT (for Inverter) Coolant (for Inverter)

73. ADD COOLANT (for Engine) Coolant (for Engine)

74. INSPECT HYBRID TRANSAXLE FLUID Adjustments

75. INSPECT FOR HYBRID TRANSAXLE FLUID LEAK

76. INSPECT FOR COOLANT LEAK (for Inverter) Testing and Inspection

77. INSPECT FOR COOLANT LEAK (for Engine) Cooling System

78. INSPECT FOR EXHAUST GAS LEAK

79. INSTALL NO. 1 ENGINE UNDER COVER

80. INSTALL FRONT LOWER BUMPER ABSORBER

81. INSTALL REAR ENGINE UNDER COVER LH

82. INSTALL REAR ENGINE UNDER COVER RH

83. INSTALL FRONT WHEELS Installation

84. INSTALL HOOD SUB-ASSEMBLY

(a) Install the hood sub-assembly with the 4 bolts.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

(b) Connect the clamp and washer hose.

85. INSPECT HOOD SUB-ASSEMBLY Testing and Inspection

86. ADJUST HOOD SUB-ASSEMBLY Adjustments

87. INSTALL RADIATOR SUPPORT OPENING COVER Installation

88. INSTALL NO. 2 CYLINDER HEAD COVER Installation

89. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Front Wheel Alignment

90. CHECK ABS SPEED SENSOR SIGNAL

Test Mode Procedure
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