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Home >> Lexus >> 2011 >> CT 200h 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.

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 NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY LH Installation

25. CONNECT FRONT NO. 1 LOWER 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 (w/ Exhaust Heat Recirculation System) Installation

35. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/o Exhaust Heat Recirculation System) Installation

36. INSTALL FRONT CENTER FLOOR BRACE Installation

37. INSTALL FRONT NO. 3 ENGINE UNDER COVER Installation

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

39. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

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 (86 kgf-cm, 74 in-lbf)

(b) 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





(c) Connect the wire harness with the 2 clamps.

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

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

(f) Connect the connector to the ECM with the 2 clamps and lock lever.

42. CONNECT NO. 5 INVERTER COOLING HOSE Installation

43. CONNECT NO. 3 INVERTER COOLING HOSE Installation

44. INSTALL RADIATOR PIPE Installation

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

46. CONNECT NO. 1 RADIATOR HOSE Installation

47. INSTALL INVERTER TRAY BRACKET Installation

48. INSTALL INVERTER RESERVE TANK ASSEMBLY Installation

49. INSTALL INVERTER WITH CONVERTER ASSEMBLY Installation

50. CONNECT WATER HOSE Installation

51. CONNECT NO. 2 ENGINE ROOM WIRE Installation

52. REMOVE INVERTER COVER Installation

53. CONNECT NO. 2 ENGINE WIRE Installation

54. CONNECT MOTOR CABLE Installation

55. CONNECT GENERATOR CABLE Installation

56. CONNECT FRAME WIRE Installation

57. CHECK HIGH VOLTAGE CABLE CONNECTION Installation

58. INSTALL INVERTER COVER Installation

59. CONNECT ENGINE ROOM MAIN WIRE Installation

60. INSTALL NO. 1 INVERTER BRACKET Installation

61. INSTALL AIR CLEANER HOSE ASSEMBLY Installation

62. INSTALL AIR CLEANER CASE Installation

63. INSTALL INLET AIR CLEANER Installation

64. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

65. INSTALL SERVICE PLUG GRIP Installation

66. CONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

67. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE Installation

68. INSTALL DECK FLOOR BOX RH Installation

69. INSTALL REAR NO. 3 FLOOR BOARD Installation

70. INSTALL REAR DECK FLOOR BOX Installation

71. INSTALL REAR NO. 2 FLOOR BOARD Installation

72. ADD HYBRID TRANSAXLE FLUID Adjustments

73. ADD COOLANT (for Inverter) Service and Repair

74. ADD COOLANT (for Engine) Service and Repair

75. INSPECT HYBRID TRANSAXLE FLUID Adjustments

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

77. INSPECT FOR COOLANT LEAK (for Engine) Testing and Inspection

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 WHEEL Installation

84. INSTALL HOOD SUB-ASSEMBLY

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

Torque : 13 Nm (132 kgf-cm, 10 ft-lbf)

(b) Connect the clamp and washer hose.

85. INSPECT HOOD SUB-ASSEMBLY

86. ADJUST HOOD SUB-ASSEMBLY Adjustments

87. INSTALL SUSPENSION TOWER DAMPER Installation

88. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

89. INSTALL COWL BODY MOUNTING REINFORCEMENT LH Installation

90. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL Installation

91. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL Installation

92. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Installation

93. INSTALL NO. 2 CYLINDER HEAD COVER Installation

94. INSTALL RADIATOR SUPPORT OPENING COVER Installation

95. INSTALL INVERTER COVER ASSEMBLY LH (w/ Cover) Installation

96. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Front Wheel Alignment

97. CHECK ABS SPEED SENSOR SIGNAL

Test Mode Procedure
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