RM38T0EC _52 Drivetrain _144756 PB10 HYBRID TRANSMISSION / TRANSAXLE _0603116 HYBRID VEHICLE TRANSAXLE A

PB10 HYBRID TRANSMISSION / TRANSAXLE HYBRID VEHICLE TRANSAXLE INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

3.49,0.552 4.323,0.719 0.833,0.167 5.302,5.135 5.969,5.302 0.667,0.167 2.01,1.448 2.76,1.615 0.75,0.167 0.26,2.708 1.01,2.875 0.75,0.167 0.583,3.323 1.333,3.49 0.75,0.167 2.938,0.99 3.688,1.156 0.75,0.167 1.333,3.406 1.667,3.406 false 2.156,3.396 2.156,3.729 false 1.375,2.583 1.708,2.583 false 2.76,1.531 3.094,1.531 false 3.688,1.073 4.021,1.073 false 4.792,0.802 5.125,0.802 false 5.635,4.802 5.635,5.135 false 1.01,2.792 1.344,2.792 false 4.323,0.635 4.656,0.635 false 1.375,2.583 1.708,2.583 false 5.323,4.427 5.656,4.427 false 2.771,0.948 3.052,1.302 0.281,0.354 18 false 1 3.302,0.51 3.583,0.865 0.281,0.354 18 false 2 1.813,1.417 2.094,1.771 0.281,0.354 18 false 3 1.208,2.448 1.49,2.802 0.281,0.354 18 false 4 2.094,3.74 2.375,4.094 0.281,0.354 18 false 5 5.698,4.292 5.979,4.646 0.281,0.354 18 false 6 3.198,1.458 3.51,1.656 0.313,0.198 10 false x2 5.719,4.677 6.031,4.875 0.313,0.198 10 false x2 3.563,0.563 4.396,0.729 0.833,0.167 8 false 39.2 (400, 29) 2.99,1 3.74,1.167 0.75,0.167 8 false 11.3 (115, 8) 2.083,1.458 2.833,1.625 0.75,0.167 8 false 30 (306, 22) 0.656,3.333 1.406,3.5 0.75,0.167 8 false 20 (204, 15) 0.323,2.719 1.073,2.885 0.75,0.167 8 false 19 (194, 14) 5.365,5.146 6.115,5.313 0.75,0.167 8 false 12 (122, 9) 1.646,1.458 1.802,1.656 0.156,0.198 10 false ★ 5.167,0.708 5.323,0.906 0.156,0.198 10 false ●

Procedure		Part Name Code
1	TRANSAXLE BREATHER PLUG	30900N	-	-	-
2	TRANSAXLE HOUSING PLUG	-	-	-	-
3	STUD BOLT	-	(202307,999999,_52,_144756,_0603116,RM100000002BO7P_01_0368,)	-	-
4	NO. 1 WATER HOSE CLAMP BRACKET	16575C	-	-	-
5	WIRE HARNESS CLAMP BRACKET	-	-	-	-
6	NO. 1 TRANSMISSION CONTROL CABLE BRACKET	33823	-	-	-

	Nm (kgfcm, ft.*lbf): Specified torque	●	Non-reusable part
	Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent	★	Precoated part

3.281,1.51 3.948,1.677 0.667,0.167 1.24,0.521 1.906,0.688 0.667,0.167 3.24,1.469 3.99,1.719 0.75,0.25 2.948,1.594 3.281,1.594 false 1.906,0.604 2.24,0.604 false 3.313,0.854 3.646,0.854 false 3.917,1.938 4.25,1.938 false 4.583,1.823 4.865,2.177 0.281,0.354 18 false 7 3.979,0.719 4.26,1.073 0.281,0.354 18 false 8 3,1.604 3.313,1.802 0.313,0.198 10 false x6 2.406,0.51 2.719,0.708 0.313,0.198 10 false x2 1.302,0.531 1.969,0.698 0.667,0.167 8 false 10 (102, 7) 3.344,1.521 4.01,1.688 0.667,0.167 8 false 10 (102, 7)

Procedure		Part Name Code
7	MOTOR CABLE	G1148	(202307,999999,_52,_144756,_0603116,RM100000002BO7P_01_0364,)	-	-
8	TERMINAL CAP	82823M	(202307,999999,_52,_144756,_0603116,RM100000002BO7P_01_0376,)	-	-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

1.438,2.542 2.188,2.708 0.75,0.167 0.281,4.208 1.198,4.375 0.917,0.167 0.521,5.302 1.271,5.469 0.75,0.167 5.583,1.677 6.333,1.844 0.75,0.167 6.094,3.385 6.844,3.552 0.75,0.167 5.24,4.271 5.99,4.438 0.75,0.167 2.188,2.625 2.521,2.625 false 6.469,3.052 6.469,3.385 false 5.615,3.938 5.615,4.271 false 5.25,1.76 5.583,1.76 false 4.01,0.958 4.344,0.958 false 1.167,4.906 1.5,4.906 false 1.271,5.385 1.604,5.385 false 4.781,4.708 5.115,4.708 false 6.156,2.438 6.49,2.438 false 1.198,4.292 1.531,4.292 false 1,4.781 1.281,5.135 0.281,0.354 18 false 9 5.125,4.573 5.677,4.927 0.552,0.354 18 false 10 4.594,0.823 5.146,1.177 0.552,0.354 18 false 11 6.531,2.354 6.844,2.552 0.313,0.198 10 false *1 1.719,5.292 2.031,5.49 0.313,0.198 10 false x5 2.698,2.531 3.01,2.729 0.313,0.198 10 false x4 5.24,1.771 5.552,1.969 0.313,0.198 10 false x2 1.521,2.552 2.271,2.719 0.75,0.167 8 false 46 (469, 34) 5.656,1.688 6.406,1.854 0.75,0.167 8 false 64 (653, 47) 5.313,4.281 6.063,4.448 0.75,0.167 8 false 25 (255, 18) 0.594,5.313 1.344,5.479 0.75,0.167 8 false 44 (449, 32) 0.344,4.219 1.26,4.385 0.917,0.167 8 false 170 (1734, 125) 6.177,3.396 6.927,3.563 0.75,0.167 8 false 46 (469, 34)

Procedure		Part Name Code
9	NO. 2 ENGINE MOVING CONTROL ROD	12364B	(202307,999999,_52,_144756,_0603116,RM100000002BO7P_01_0338,)	-	-
10	FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY	51201	-	-	-
11	ENGINE ASSEMBLY	-	(202307,999999,_52,_144756,_0603116,RM100000002BO7P_01_0340,)	-	-

*1	HYBRID VEHICLE TRANSAXLE ASSEMBLY	-	-
	Nm (kgfcm, ft.*lbf): Specified torque	-	-

5.542,3.75 6.292,3.917 0.75,0.167 6.208,3.302 6.875,3.469 0.667,0.167 0.24,3.313 0.99,3.479 0.75,0.167 0.5,4.719 1.25,4.885 0.75,0.167 6.135,0.979 6.802,1.146 0.667,0.167 0.198,3.271 1.031,3.521 0.833,0.25 1.771,0.667 2.104,0.667 false 6.531,2.969 6.531,3.302 false 4.927,2.115 5.26,2.115 false 6.135,1.063 5.802,1.063 false 1.458,5.375 1.792,5.375 false 0.917,2.333 1.25,2.333 false 5,3.104 5.333,3.104 false 5.906,3.417 5.906,3.75 false 2.26,1.531 2.594,1.531 false 4.781,0.49 5.115,0.49 false 6.427,0.24 6.76,0.24 false 0.885,4.385 0.885,4.719 false 0.615,2.979 0.615,3.313 false 1.427,4.271 1.177,3.938 1.177,3.938 1.01,3.938 false 3.302,2.677 3.552,2.344 3.552,2.344 3.719,2.344 false 6.094,2.958 6.344,2.625 6.344,2.625 6.51,2.625 false 1.823,5.24 2.375,5.594 0.552,0.354 18 false 12 0.708,3.802 1.26,4.156 0.552,0.354 18 false 13 5.135,0.354 5.688,0.708 0.552,0.354 18 false 14 0.625,2.198 1.177,2.552 0.552,0.354 18 false 15 1.979,1.396 2.531,1.75 0.552,0.354 18 false 16 2.115,0.531 2.667,0.885 0.552,0.354 18 false 17 5.271,1.969 5.823,2.323 0.552,0.354 18 false 17 4.698,2.979 5.25,3.333 0.552,0.354 18 false 18 6.542,2.479 7.094,2.833 0.552,0.354 18 false 19 3.771,2.208 4.323,2.563 0.552,0.354 18 false 20 6.146,0.115 6.698,0.469 0.552,0.354 18 false 21 1.115,1.188 1.427,1.385 0.313,0.198 10 false x2 5.448,2.448 5.76,2.646 0.313,0.198 10 false x2 5.781,1.083 6.094,1.281 0.313,0.198 10 false x2 1.052,4.25 1.365,4.448 0.313,0.198 10 false x2 5.615,3.76 6.365,3.927 0.75,0.167 8 false 43 (438, 32) 0.313,3.323 1.063,3.49 0.75,0.167 8 false 20 (204, 15) 0.573,4.729 1.323,4.896 0.75,0.167 8 false 46 (469, 34) 6.26,3.313 7.01,3.479 0.75,0.167 8 false 10 (102, 7) 6.198,0.99 6.948,1.156 0.75,0.167 8 false 10 (102, 7)

Procedure		Part Name Code
12	FLYWHEEL HOUSING SIDE COVER	11363A	-	-	-
13	STARTER HOLE INSULATOR	28193	-	-	-
14	ENGINE WIRE	82121	-	-	-
15	NO. 7 ENGINE WIRE	82127D	-	-	-
16	OUTLET NO. 1 INVERTER COOLING HOSE	G922C	(202307,999999,_52,_144756,_0603116,RM100000002BO7P_01_0382,)	-	-
17	ENGINE HANGERS	-	-	-	-
18	EMISSION CONTROL VALVE BRACKET	-	-	-	-
19	DIFFERENTIAL PRESSURE SENSOR	89481B	-	-	-
20	ENGINE ASSEMBLY WITH TRANSAXLE	-	-	-	-
21	PERFORM RESOLVER LEARNING	-	-	-	(202307,999999,_52,_144756,_0603116,RM100000002BO7P_01_0366,)

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

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

Hide Display 30900N 1.INSTALL TRANSAXLE BREATHER PLUG

HINT:: Perform this procedure only when replacement of the transaxle breather plug is necessary.

Torque:: 11.3 N*m (115 kgf*cm, 8 ft.*lbf)

Hide Display 2.INSTALL TRANSAXLE HOUSING PLUG

Torque:: 39.2 N*m (400 kgf*cm, 29 ft.*lbf)

Hide Display 3.INSTALL STUD BOLT

0.469,0.073 0.75,0.427 0.281,0.354 18 false i 3.958,0.073 4.24,0.427 0.281,0.354 18 false ii

Apply adhesive to the 2 stud bolts.

Adhesive:: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

ii.

Using an E10 "TORX" socket wrench, install the 2 stud bolts to the hybrid vehicle transaxle assembly.

Torque:: 30 N*m (306 kgf*cm, 22 ft.*lbf)

Hide Display 16575C 4.INSTALL NO. 1 WATER HOSE CLAMP BRACKET

Torque:: 19 N*m (194 kgf*cm, 14 ft.*lbf)

Hide Display 5.INSTALL WIRE HARNESS CLAMP BRACKET

Torque:: 20 N*m (204 kgf*cm, 15 ft.*lbf)

Hide Display 33823 6.INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

Torque:: 12 N*m (122 kgf*cm, 9 ft.*lbf)

Hide Display G1148 7.INSTALL MOTOR CABLE

Click here(

202307,999999,_52,_144756,_0603117,RM100000002BO7Q_01_0059,)

Hide Display 82823M 8.INSTALL TERMINAL CAP

Click here(

202307,999999,_52,_144756,_0603117,RM100000002BO7Q_01_0062,)

Hide Display 12364B 9.INSTALL NO. 2 ENGINE MOVING CONTROL ROD

0.385,0.052 0.667,0.406 0.281,0.354 18 false i 2.917,0.458 3.083,0.625 0.167,0.167 10 false A 3.583,1.24 3.75,1.406 0.167,0.167 10 true B 3.594,0.521 3.76,0.688 0.167,0.167 10 true C 2.813,0.875 2.979,1.042 0.167,0.167 10 false C 2.854,1.25 3.021,1.417 0.167,0.167 10 false C

Install the No. 2 engine moving control rod to the hybrid vehicle transaxle assembly with the 5 bolts.

Torque:: 44 N*m (449 kgf*cm, 32 ft.*lbf)

NOTICE:: Temporarily tighten the bolt (A), and then fully tighten the 5 bolts in the order of (B), (C) and (A).

Hide Display 51201 10.INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

Torque:: 170 N*m (1734 kgf*cm, 125 ft.*lbf)

Hide Display 11.INSTALL ENGINE ASSEMBLY

2.552,0.323 2.719,0.49 0.167,0.167 10 true *1 0.469,0.073 0.75,0.427 0.281,0.354 18 false i 3.958,0.073 4.531,0.427 0.573,0.354 18 false ii, iii 6.073,0.24 6.229,0.438 0.156,0.198 10 false A 5.771,0.094 5.927,0.292 0.156,0.198 10 false B 5.833,1.604 5.99,1.781 0.156,0.177 10 false C 5.99,1.5 6.146,1.698 0.156,0.198 10 false D 4.969,1.625 5.125,1.781 0.156,0.156 10 false D 4.708,1.531 4.875,1.698 0.167,0.167 10 true D 0.99,0.25 1.156,0.417 0.167,0.167 10 true *1 4.677,0.198 4.844,0.365 0.167,0.167 10 true D 4.542,0.573 4.708,0.74 0.167,0.167 10 true D

Knock Pin

Make sure that the knock pins are installed to the engine assembly.

ii.

Align the knock pins with the holes in the hybrid vehicle 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 engine 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 engine assembly excessively.

·

When installing the engine assembly to the hybrid vehicle transaxle assembly, make sure to securely fit the knock pins into the knock pin holes.

iii.

While keeping the contact surfaces of the engine assembly and hybrid vehicle transaxle assembly in close contact with one another, install the 8 bolts.

Torque:: Bolt (A), (B) : 64 N*m (653 kgf*cm, 47 ft.*lbf); Bolt (C) : 25 N*m (255 kgf*cm, 18 ft.*lbf); Bolt (D) : 46 N*m (469 kgf*cm, 34 ft.*lbf)

Bolt	Bolt Length
(A), (B)	50 mm (1.97 in.)
(C)	35 mm (1.38 in.)
(D)	45 mm (1.77 in.)

Hide Display 11363A 12.INSTALL FLYWHEEL HOUSING SIDE COVER

Hide Display 28193 13.INSTALL STARTER HOLE INSULATOR

Torque:: 46 N*m (469 kgf*cm, 34 ft.*lbf)

Hide Display 82121 14.CONNECT ENGINE WIRE

Torque:: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Hide Display 82127D 15.INSTALL NO. 7 ENGINE WIRE

Torque:: 20 N*m (204 kgf*cm, 15 ft.*lbf)

Hide Display G922C 16.INSTALL OUTLET NO. 1 INVERTER COOLING HOSE

5.052,1.135 5.313,1.135 5.313,1.135 5.052,0.979 true 6.24,1.094 6.146,1.229 true 5.354,1.052 5.667,1.25 0.313,0.198 10 false *a 4.438,0.896 4.75,1.094 0.313,0.198 10 false *b 6.073,1.208 6.281,1.427 0.208,0.219 10 false *a 0.385,0.052 0.667,0.406 0.281,0.354 18 false i 6.792,1.198 6.99,1.396 0.198,0.198 10 false *c 5.698,1.177 5.896,1.375 0.198,0.198 10 false *d

*a	Paint Mark	*b	2 to 11 mm (0.0787 to 0.433 in.)
*c	115°	*d	275° (Claw of Clip Location)

Install the outlet No. 1 inverter cooling hose to the motor cooling cooler and slide the clip to secure it.

NOTICE:: ·

Make sure to slide the outlet No. 1 inverter cooling hose until it contacts the hose stopper of the motor cooling cooler.

·

Make sure to align the paint mark of the outlet No. 1 inverter cooling hose with the paint mark of the motor cooling cooler.

·

Make sure that the claws of the clip are within the location shown in the illustration.

Hide Display 17.REMOVE ENGINE HANGERS

Hide Display 18.INSTALL EMISSION CONTROL VALVE BRACKET

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202307,999999,_51,_144958,_0604262,RM100000002BTSX_01_0451,

Hide Display 89481B 19.INSTALL DIFFERENTIAL PRESSURE SENSOR

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (EMISSION CONTROL)>DIFFERENTIAL PRESSURE SENSOR>INSTALLATION202307,999999,_51,_144996,_0604955,RM100000002BX8V_01_0042,

Hide Display 20.INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>INSTALLATION202307,999999,_51,_144958,_0604262,RM100000002BTSX,

Hide Display 21. PERFORM RESOLVER LEARNING

NOTICE:: If the hybrid vehicle transaxle assembly has been replaced, make sure to perform resolver learning.; Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>MOTOR GENERATOR CONTROL SYSTEM>UTILITY202307,999999,_51,_144957,_0604233,RM100000002BW44,