Hybrid Vehicle Transaxle ASSY: Overhaul

1. Install the engine hanger in the position shown in the illustration.

   HINT:

   • Engine hanger 12281-67070, S1228-11781
   • Bolt 91642-81045, 91642-81265
   • Nut 90178-10001, 90179-12147
2. Using an engine sling device and chain block, set the transaxle assy with the generator side facing upward.
   NOTE:

   • Fix the transaxle assy on a wooden block, etc.
   • Fix the transaxle assy so that no excessive force is applied to the cable.
3. Remove the drain plug.
   Fig 1: Installing Engine Hanger

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4. Remove the 21 bolts shown in the illustration.

   HINT:

   • 13 bolts on the generator assy side.
   • 8 bolts on the motor assy side.
   Fig 2: Removing Bolts

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5. Separate the motor assy and generator assy by inserting a flat-head screwdriver in the position shown and prying the two apart.
   NOTE: Be careful not to damage the two faces of each part.
6. Using an engine sliding device and a chain block, raise the generator assy.

   HINT:

   Raise the generator assy approximately 3 to 4 cm.

   Fig 3: Raising Generator Assy

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7. Apply protective tape to the head of a flat-head screwdriver and use it to hold down the chain with input shaft assy while removing the generator assy.
   Fig 4: Removing Counter Driven Gear From HV Motor

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8. REMOVE DIFFERENTIAL DRIVE PINION 
9. Remove the counter driven gear from the HV motor.

Fig 5: Removing Counter Driven Gear From HV Motor

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1. Remove the differential case assy from the HV motor.

Fig 6: Removing Differential Case Assy. From HV Motor

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1. Remove the thrust bearing race, thrust needle roller bearing and thrust bearing race No.1.

   HINT:

   The thrust bearing race may be attached to the generator assy side.

   Fig 7: Removing Thrust Bearing Race, Needle Roller Bearing And Thrust Bearing Race No 1

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2. Remove the drive sprocket and chain.

Fig 8: Removing Drive Sprocket And Chain

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1. Remove the input shaft assy.

Fig 9: Removing Input Shaft Assy

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1. Remove the thrust bearing race, thrust needle roller bearing and thrust bearing race No.1.

   HINT:

   The thrust bearing race may be attached to the input shaft side.

   Fig 10: Removing Thrust Learning Race, Thrust Needle Roller Bearing And Thrust Bearing Race No-1

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2. Remove the planetary ring rear.

Fig 11: Removing Planetary Ring Rear

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1. Remove the planetary ring gear flange and shim.

Fig 12: Removing Planetary Ring Gear Flange And Shim

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1. Use a plastic hammer to tap the motor assy case and remove the counter drive gear and shim.

HINT:

Remove the counter drive gear while pulling it vertically.

Fig 13: Removing Counter Drive Gear And Shim

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1. Remove the bolt and oil strainer.
   Fig 14: Removing Bolt And Oil Strainer

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2. Remove the O-ring from the oil strainer.

Fig 15: Removing O-Ring

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1. Fix the motor assy on a wooden block, etc.

Fig 16: Fixing Motor Assy In Wooden Block

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1. Remove the 3 bolts and mounting bracket. 

Fig 17: Removing Mounting Bracket

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1. Remove the bolt and pull out the HV motor side motor revolution sensor wire harness connector (gray).
   NOTE: Do not pull on the connector any more than necessary.
2. Remove the connector and motor revolution sensor wire harness connector (gray).

Fig 18: Removing Connector And Motor Revolution Sensor Wire Harness Connector

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1. Remove the bolt and pull out the motor stator wire harness connector (black).
   NOTE: Do not pull on the sensor connector any more than necessary.
2. Remove the connector and the motor stator wire harness connector (black).

Fig 19: Removing Motor Stator Wiring Harness Connector

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1. Remove the 3 bolts and shift control actuator assy.

Fig 20: Removing Shift Control Actuator Assy

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1. Remove the 6 bolts and the parking cover.

Fig 21: Removing Parking Cover

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1. Remove the bolt, manual detent spring cover and manual detent spring.

Fig 22: Removing Manual Detent Spring Cover And Manual Detent Spring

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1. Remove the 6 bolts and motor water jacket cover.

Fig 23: Removing Motor Water Jacket Cover

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1. Remove the 5 bolts and the parking shaft cover.

Fig 24: Removing Parking Shaft Cover

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1. Remove the oil pump cover plug and O-ring.
   Fig 25: Removing Oil Plump Plug And O-Ring

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2. Remove the 5 bolts and oil pump cover.
   Fig 26: Removing Oil Pump Cover

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3. Remove the O-ring.

Fig 27: Removing O-Ring

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1. Remove the oil pump drive rotor and oil pump driven rotor.
   Fig 28: Removing Oil Pump Drive And Driven Rotor

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2. Remove the oil pump drive shaft.

Fig 29: Removing Oil Pump Drive Shaft

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1. Using SST, remove the differential case tapered roller bearing LH outer race and shim. SST 09308-00010

Fig 30: Removing Differential Case Tapered Roller Bearing LH Outer Race And Shim

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1. Fix the motor assy on a wooden block, etc.
   NOTE: Do not use a wooden block with the parking lock rod.
   Fig 31: Fixing Motor Assy On Wooden Block

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2. Using SST, remove the oil seal.
   1. SST 09308-00010

Fig 32: Removing Oil Seal

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1. Remove the set plug and gasket.
2. Using a hexagon wrench (10 mm), remove the screw plugs.

Fig 33: Removing Screw Plugs

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1. Fix the generator assy on a wooden block, etc.

Fig 34: Fixing Generator Assy. On Wooden Block

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1. Remove the breather plug.
   Fig 35: Removing Breather Plug

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2. Remove the 4 bolts and power cable cover.

Fig 36: Removing Power Cable Cover

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1. Remove the 5 bolts and generator cable.

Fig 37: Removing Generator Cable

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1. Remove the bolt and pull out the HV generator side generator revolution sensor wire harness connector.
   NOTE: Do not pull on the sensor connector any more than necessary.
2. Disconnect the connector and the HV generator side generator revolution sensor wire harness connector.

Fig 38: Removing HV Generator Side Generator Revolution Sensor Wire Harness Connector

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1. Remove the transaxle housing tube connector.

Fig 39: Removing Transaxle Housing Tube Connector

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1. Using SST, remove the oil seal.
   1. SST 09612-30012

Fig 40: Removing Oil Seal

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1. Using SST, remove the oil seal.
   1. SST 09308-00010

Fig 41: Removing Oil Seal

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1. Using SST, remove the differential case tapered roller bearing LH outer race.
   1. SST 09308-00010

Fig 42: Removing Differential Case Tapered Roller Bearing LH Outer Race

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1. Remove the set plug and gasket.
2. Using a socket wrench (6 mm), remove the screw plug.

Fig 43: Removing Set Plug, Screw Plug And Gaskets

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1. Inspect the inside diameter of the rotor bush
   1. Using a dial indicator, measure the inside diameter of the motor assy rotor bush.
      1. Standard diameter: 
      2. 20.025 to 20.046 mm (0.78838 to 0.78921 in.) 
      3. Maximum diameter: 
      4. 20.096 mm (0.79118 in.) 
   Fig 44: Measuring Inside Diameter Of Motor Assy. Rotor Bush

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Take the measurement in different locations and use the average of the measurements taken.

   HINT:

   If the inside diameter exceeds the maximum, replace the motor assy with a new one.

1. Install a new gasket and the set plug.
   1. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 
2. Apply liquid sealant 1344 to the first 2 to 3 threads from the end of the screw plug.
   NOTE: Clean and degrease the screw and screw hole.
3. Using a socket hexagon wrench (6 mm), install the screw plug.
   1. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) 

Fig 45: Installing Set Plug, Screw Plug And Gasket

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1. Install a new gasket and the set plug.

   Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

   HINT:

   Tighten the set plug after adding transaxle oil.

2. Apply liquid sealant 1324 to the first 2 to 3 threads from the end of the screw plug.
   NOTE: Clean and degrease the screw and screw hole.
3. Using a socket hexagon wrench (10 mm), install the screw plug.
   1. Torque: 55 N.m (561 kgf.cm, 41 ft.lbf) 

Fig 46: Installing Gasket And Set Plug

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1. Using SST, install a new oil seal.
   1. Oil seal depth: 2.7 +/- 0.5 mm (0.106 +/- 0.020 in.) 
2. Coat the lip of the oil seal with MP grease No.2.
   1. SST 09350-32014 (09351-32130, 09351-32150), 09950-70010 (09951-07100)

Fig 47: Installing Oil Seal

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1. Fix the motor assy on a wooden block, etc.
   NOTE: Do not use a wooden block with the parking lock rod.
   Fig 48: Fixing Motor Assy On Wooden Block

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, install the oil seal.
   1. Oil seal depth: 2.7 +/- 0.5 mm (0.106 +/- 0.020 in.) 
3. Coat the lip of the oil seal with MP grease No.2.
   1. SST 09350-32014 (09351-32130, 09351-32150), 09950-70010 (09951-07100)

Fig 49: Installing Oil Seal

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1. Adjust the differential case assy preload.
   1. Fix the motor assy on a wooden block, etc.
      NOTE:

      • Fix the motor assy horizontally.
      • Unreasonable force should not be applied to the cable.
      Fig 50: Fixing Motor Assy On Wooden Block

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Using SST, install the differential case tapered roller bearing LH outer race and shim to the motor assy.
      1. SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)
      NOTE: Replace the shim and outer race with new ones if they are deformed or damaged.
      Fig 51: Installing Differential Case Tapered Roller Bearing LH Outer Race And Shim To Motor Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Using SST, install the differential case tapered roller bearing RH outer race to the generator assy.
      1. SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)
      NOTE: Replace the outer race with a new one if it is deformed or damaged.
      Fig 52: Installing Differential Case Tapered Roller Bearing RH Outer Race To Generator Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. Apply ATF WS to the sliding surfaces of the differential case tapered roller bearing and install to the motor assy.
      Fig 53: Applying ATF WS To Sliding Surface Of Differential Case Tapered Roller Bearing And Installing To Motor Assy

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   5. Using an engine sling device and chain block, install the motor assy to the generator assy.

      HINT:

      • Engine hanger 12281-67070, S1228-11781
      • Bolt 91642-81045, 91642-81265
      • Nut 90178-10001, 90179-12147
      Fig 54: Installing Motor Assy To Generator Assy

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   6. Tighten the 13 bolts in the positions shown in the illustration.
      1. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 
      Fig 55: Tightening Bolt

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   7. Using SST, rotate the differential case assy in both directions to stabilize the bearings.
      1. SST 09564-32011
      Fig 56: Rotating Differential Case Assy In Both Direction To Stabilize Bearing

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   8. Using SST, measure the differential preload of the differential case assy and rotation torque.
      1. SST 09564-32011 
      2. Preload (Starting torque): 
      3. New bearing 
      4. 0.98 to 1.57 N.m 
      5. (9.99 to 16.01 kgf.cm, 8.67 to 13.90 in.lbf) 
      6. Reused bearing 
      7. 0.49 to 0.78 N.m 
      8. (5.00 to 7.95 kgf.cm, 4.34 to 6.90 in.lbf) 
      9. Preload (Turning torque): 
      10. 0.61 to 1.35 N.m (20 RPM) at 20 °C 
      11. (6.2 to 13.77 kgf.cm, 5.4 to 11.95 in.lbf) 
      Fig 57: Measuring Differential Preload Of Differential Case Assy And Rotation Torque

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      • If the preload is not within the specified range, select the shim to replace.
      • Remove the motor assy side tapered roller bearing outer race and shim when replacing the shim.
      • Replace the shim and outer race with new ones if they are deformed or damaged.
      • As the shim thickness is increased 0.02 mm (0.0008 in.), the preload increases approximately 0.23 N.m (2.4 kgf-cm 2.04 in. lbf) accordingly.

      Shim Types 

      SHIM TYPES AND THICKNESS
      
      

      Parts Number	Thickness mm (in.)	Mark
      90564-45040	1.80 (0.0709)	1
      90564-45041	1.83 (0.0720)	2
      90564-45042	1.86 (0.0732)	3
      90564-45043	1.89 (0.0744)	4
      90564-45071	1.92 (0.0756)	50
      90564-45072	1.94 (0.0764)	51
      90564-45073	1.96 (0.0722)	52
      90564-45074	1.98 (0.0780)	53
      90564-45075	2.00 (0.0787)	54
      90564-45076	2.02 (0.0795)	55
      90564-45077	2.04 (0.0803)	56
      90564-45078	2.06 (0.0811)	57
      90564-45079	2.08 (0.0819)	58
      90564-45080	2.10 (0.0827)	59
      90564-45081	2.12 (0.0835)	60
      90564-45082	2.14 (0.0843)	61
      90564-45083	2.16 (0.0850)	62
      90564-45084	2.18 (0.0858)	63
      90564-45085	2.20 (0.0866)	64
      90564-45086	2.22 (0.0874)	65
      90564-45087	2.24 (0.0882)	66
      90564-45088	2.26 (0.0890)	67
      90564-45089	2.28 (0.0898)	68
      90564-45090	2.30 (0.0906)	69
      90564-45091	2.32 (0.0913)	70
      90564-45060	2.34 (0.0921)	19
      90564-45061	2.37 (0.0933)	20
      90564-45011	2.40 (0.0945)	No indication
      90564-45062	2.43 (0.0957)	22
      90564-45063	2.46 (0.0969)	23

   9. Using an engine sling device and chain block, remove the 13 bolts and generator assy.

1. Install the differential drive pinion.

1. Select the input shaft shim.
   Fig 58: Installing Differential Drive Pinion

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   1. Install the thrust bearing race No.1.
   2. Apply ATF WS to the sliding surfaces of the thrust needle roller flange and install.
   3. Install the thrust bearing race.
      Fig 59: Installing Thrust Bearing Race No-1

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   4. Install the drive sprocket.
      Fig 60: Installing Drive Sprocket

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   5. Install the input shaft assy.
      Fig 61: Installing Shaft Assy

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   6. Install the thrust bearing race No.1.
   7. Apply ATF WS to the sliding surfaces of the thrust needle roller flange and install.
   8. Install the thrust bearing race.
      Fig 62: Installing Thrust Bearing Race No-1

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   9. Install the planetary ring gear.
      Fig 63: Installing Planetary Ring Gear

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   10. Install the planetary ring gear flange.
       Fig 64: Installing Planetary Ring Gear Flange

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   11. Using a straight edge and vernier calipers, measure dimension A as shown in the illustration.

       Standard value: Dimension A = Measured value-width of straight edge used 

       NOTE:

       • Measure dimension A without the shim installed. Take the measurement 3 times each in 3 different locations and use the average of the measurements taken.
       • Two people are required for this step because it is difficult to keep the straight edge level. One person should hold the straight edge, and the other person measure dimension A.
   12. Using a straight edge and vernier calipers, measure dimension B as shown in the illustration.

       Standard value: Dimension B = Measured value-thickness of straight edge used 

       NOTE: Dimension B is greater than dimension A.
       Fig 65: Measuring Dimension A And B Using Vernier Caliper

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   13. Select a shim.

       Standard value: Select shim = (Dimension B-Dimension A) - 0.1 mm (0.0039 in.) to 0.4 mm (0.0157 in.) 

   NOTE: Subtract 0.1 mm (0.0039 in.) to 0.4 mm (0.0157 in.) from the difference of Dimension B and Dimension A and select a shim on the basis of the resulting value. This is done because clearance 0.1 mm (0.0039 in.) to 0.4 mm (0.0157 in.) with the input shaft is required.

   Shim Types 

   SHIM TYPES AND THICKNESS
   
   

   Parts Number	Thickness mm (in.)	Mark
   90564-36021	1.00 (0.0394)	1
   90564-36022	1.20 (0.0472)	2
   90564-36023	1.40 (0.0551)	3
   90564-36024	1.60 (0.0630)	4
   90564-36025	1.80 (0.0709)	5
   90564-36026	2.00 (0.0787)	6
   90564-36027	2.20 (0.0866)	7
   90564-36028	2.40 (0.0945)	8
   90564-36029	2.60 (0.1024)	9
   90564-36030	2.80 (0.1102)	10
   90564-36031	3.00 (0.1181)	11
   90564-36032	3.20 (0.1260)	12

2. Select a counter drive gear shim.
   1. Install the counter drive gear.
      NOTE:

      • Insert the counter drive gear vertically.
      • Ensure that the counter drive gear is fully inserted.
      Fig 66: Installing Connector Drive Gear

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   2. Using a straight edge and vernier calipers, measure dimension A as shown in the illustration.

      Standard value: Dimension A = Measured value-width of straight edge used 

      NOTE:

      • Measure dimension A without the shim installed.
      • Take the measurement 3 times each in 3 different locations and use the average of the measurements taken.
      • Two people are required for this step because it is difficult to keep the straight edge level. One person should hold the straight edge, and the other person measure dimension A.
   3. Using a straight edge and vernier calipers, measure dimension B as shown in the illustration.

      Standard value: Dimension B = Measured value-thickness of straight edge used 

      NOTE: Dimension B is greater than dimension A.
      Fig 67: Measuring Dimension A And B Using Vernier Caliper

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   4. Select a shim.

      Standard value: Selected shim = (Dimension B-Di-mension A) - 0 mm (0 in.) to 0.1 mm (0.0039 in.) 

   NOTE: Subtract 0 mm (0 in.) to 0.1 mm (0.0039 in.) from the difference of Dimension B and Dimension A and select a shim on the basis of the resulting value. This is done because clearance 0 mm (0 in.) to 0.1 mm (0.0039 in.) with the counter drive gear is required.

   Shim Types 

   SHIM TYPE AND THICKNESS
   
   

   Parts Number	Thickness mm (in.)	Marks
   90564-35132	2.20 (0.0866)	A
   90564-35133	2.25 (0.0886)	B
   90564-35134	2.30 (0.0906)	C
   90564-35135	2.35 (0.0925)	D
   90564-35136	2.40 (0.0945)	E
   90564-35137	2.45 (0.0965)	F
   90564-35138	2.50 (0.0984)	G
   90564-35139	2.55 (0.1003)	H
   90564-35140	2.60 (0.1024)	J
   90564-35141	2.65 (0.1043)	K
   90564-35142	2.70 (0.1063)	L
   90564-35143	2.75 (0.1083)	M
   90564-35144	2.80 (0.1102)	N

1. Install the shim selected.
   Fig 68: Installing Shim

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2. Install the planetary ring gear flange.
3. Install the thrust bearing race No.1.
4. Install the thrust needle roller bearing.
   1. Apply ATF WS to the sliding surfaces of the thrust needle roller flange and install.
5. Install the thrust bearing race.
   Fig 69: Installing Planetary Ring Gear Flange, Thrust Bearing, Thrust Needle Roller Bearing And Thrust Needle Roller Bearing

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6. Install the planetary ring gear.
   Fig 70: Installing Planetary Ring Gear

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7. Install the input shaft assy.

Fig 71: Installing Input Shaft Assembly

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1. Install the counter drive gear selected.
   Fig 72: Installing Counter Drive Gear

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2. Install the counter drive gear and chain.

Fig 73: Installing Counter Drive Gear And Chain

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1. Apply ATF WS auto fluid to the drive sprocket needle roller bearing and put the drive sprocket on the chain.
2. Align the recesses of the planetary ring gear and the drive sprocket and install the drive sprocket with chain.

Fig 74: Installing Transmission Drive Sprocket Sub-Assy

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1. Install the drive sprocket thrust needle roller bearing No.1.
2. Install the thrust bearing race No.2.

Fig 75: Installing Drive Sprocket Thrust Needle Roller Bearing No-1 And Thrust Bearing Race No.2

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1. Apply ATF WS to a new O-ring and install the fluid strainer.
   Fig 76: Applying ATF WS To New O-Ring And Installing Fluid Strainer

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2. Install the bolt and oil strainer.
   1. Torque: 7.9 N.m (81 kgf.cm, 70 in.lbf) 

Fig 77: Locating Position To Install Bolt And Oil Strainer

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1. Apply seal packing 1281 in a continuous line of beads (diameter 1.5 mm 0.059 in.) to the motor assy side.
   NOTE:

   • Clean and degrease the installation surfaces.
   • Install within 10 minutes of applying seal packing.
   Fig 78: Applying Seal Packing In A Continous Line To Motor Assy Side

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2. Install the parking lock rod to the generator assy so that it is inserted into the cam guide sleeve. Use an engine sling device and chain block.
   NOTE: Rotate the input shaft in both directions so that the gears interlock if the generator assy cannot be easily installed.
   Fig 79: Installing Parking Lock Rod To Generator Assy

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   Fig 80: Rotating Input Shaft In Both Directions

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3. Apply liquid sealant 1344 to the first 2 to 3 threads of the bolt (45 mm 1.772 in. long shaft) end.
   NOTE: Clean and degrease the bolt and bolt holes.
4. Install the 21 bolts as shown in the illustration.
   1. Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

HINT:

• 13 bolts on the generator assy side
• 8 bolts on the motor assy side

Fig 81: Installing Bolts

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1. Coat the lip of the oil seal with MP grease No.2.
   NOTE: Ensure that no foreign objects adhere to the oil seal lip.
2. Using SST, install a new oil seal.

   Oil seal depth: 1 to 1.5 mm (0.039 to 0.059 in.) 

Fig 82: New Oil Seal

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1. Set the hybrid transaxle as shown in the illustration.

Fig 83: Locating Setting Of Hybrid Transaxle

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1. Apply seal packing 1281 in a continuous line of beads (diameter 1.5 mm, 0.06 in) as shown in the illustration.
   NOTE:

   • Clean and degrease the installation surfaces.
   • Install within 10 minutes of applying seal packing.
   Fig 84: Applying Seal Packing On Parking Cover

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2. Install the 5 bolts and parking shaft cover.
   1. Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) 

Fig 85: Installing Parking Shaft Cover

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1. Apply seal packing black in a continuous line of beads (diameter 1.5 mm, 0.06 in) as shown in the illustration.
   NOTE:

   • Clean and degrease the installation surfaces.
   • Install within 10 minutes of applying seal packing.
   Fig 86: Applying Seal Packing On Motor Water Jacket Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Apply liquid sealant 1344 to the first 2 to 3 threads of each of the 6 bolts. Install the motor water jacket cover with the 6 bolts.
   1. Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) 

Fig 87: Locating 6 Bolts Of Motor Water Jacket Cover

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1. Apply liquid sealant 1344 to the first 2 to 3 threads of the bolt and install.
   1. Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 
   NOTE: Clean and degrease the bolt and bolt holes.
2. Install the drain plug using a new gasket.
   1. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

Fig 88: Installing Drain Plug

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1. Install the manual detent spring and manual detent spring cover using the bolt.
   1. Torque: 9.8 N.m (100 kgf.cm, 86 in.lbf) 

Fig 89: Installing Manual Detent Spring And Manual Detent Spring Cover

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1. Apply seal packing 1281 in a continuous line of beads (diameter 1.5 mm, 0.06 in) as shown in the illustration.
   NOTE:

   • Clean and degrease the installation surfaces.
   • Install within 10 minutes of applying seal packing.
   Fig 90: Applying Seal Packing On Parking Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the parking cover with the 6 bolts.
   1. Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) 

Fig 91: Installing Parking Cover

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1. Apply a small amount of genuine ATF WS to the O-ring.
   Fig 92: Applying ATF WS To O-Ring

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2. Install the shift control actuator with the 3 bolts.
   1. Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 
3. Install the transmission case cover with the 3 bolts.

Fig 93: Installing Transmission Case Cover

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1. Apply ATF WS to the fluid pump drive shaft and install.

Fig 94: Installing Fluid Pump Drive Shaft

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1. Apply ATF WS to the fluid pump driven rotor and install.

Fig 95: Installing Oil Pump Driven Rotor

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1. Apply ATF WS to the transaxle fluid pump drive rotor and install.

Fig 96: Installing Transaxle Oil Pump Drive Rotor

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1. Install a new O-ring.
   NOTE: Ensure that the O-ring is not twisted.
   Fig 97: Locating New O-Ring

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2. Apply liquid sealant 1344 to the first 2 to 3 threads of the bolt end.
   NOTE: Clean and degrease the bolts and bolt holes.
3. Install the oil pump cover with the 5 bolts.
   1. Torque: 5.5 N.m (56 kgf.cm, 49 in.lbf) 
   Fig 98: Installing Oil Pump Cover

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4. Install a new O-ring and install the fluid pump cover plug.
   1. Torque: 7.4 N.m (75 kgf.cm, 65 in.lbf) 

Fig 99: Installing New O-Ring And Install Fluid Pump Cover Plug

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1. Apply ATF WS to the O-ring and install the motor stator wiring harness connectors (black) with the bolt.
   1. Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf) 

Fig 100: Locating Motor Stator Wiring Harness Connector

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1. Apply ATF WS to the O-ring and install the HV motor side motor revolution sensor wiring harness connectors (gray) with the bolt.
   1. Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf) 

Fig 101: Locating Motor Revolution Sensor Wiring Harness Connector

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1. Apply ATF WS to the O-ring and install the HV generator side generator motor revolution sensor wiring harness connector with the bolt.
   1. Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf) 

Fig 102: Locating Generator Motor Revolution Sensor Wiring Harness Connector

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1. Align the generator cables as shown in the illustration and connect.
   NOTE:

   • Connect by aligning the letters U, V and W.
   • Apply a small amount of ATF WS to the O-ring.
2. Apply liquid sealant to the first 2 or 3 threads of bolts B and install the generator cable with the bolts.
   1. Torque: 5.8 N.m (59 kgf.cm, 51 in.lbf) (bolt B) 
   Fig 103: Locating Generator Cable

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   NOTE: Clean and degrease the bolts and bolt holes.
3. Install the generator cable with the 3 bolts (A).
   1. Torque: 8.5 N.m (87 kgf.cm, 75 in.lbf) (bolt A) 

1. Apply seal packing 1281 in a continuous line of beads (diameter 1.5 mm 0.06 in.) as shown in the illustration.
   NOTE:

   • Clean and degrease the installation surfaces.
   • Install within 10 minutes of applying seal packing.
   Fig 104: Applying Seal Packing On Power Cable Cover

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2. Apply liquid sealant 1344 to the first 2 or 3 threads of the 4 bolts and install the power cable cover.
   1. Torque: 4.8 N.m (49 kgf.cm, 42 in.lbf) 
   NOTE: Clean and degrease the bolts and bolt holes.
   Fig 105: Installing Power Cable Cover

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3. Install the breather plug.
   1. Torque: 11 N.m (112 kgf.cm, 8.1 ft.lbf) 

Fig 106: Installing Breather Plug

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1. Apply liquid sealant 1344 to the first 2 or 3 threads of the 3 bolts and install the engine mounting bracket.
   1. Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 

Fig 107: Installing Engine Mounting Bracket No.3

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