Installation

L110 HYBRID TRANSMISSION / TRANSAXLE: HYBRID VEHICLE TRANSMISSION: INSTALLATION

1. INSTALL WIRE HARNESS CLAMP

(a) Align the matchmarks and install 9 new clamps and wire harness protector to the wire.

(b) Using tape or equivalent, cover the area indicated in the illustration.

2. INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY

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

(b) Install the hybrid vehicle transmission to the engine with the 9 bolts shown in the illustration.

for Bolt A - Torque : 71 Nm (724 kgf-cm, 52 ft-lbf)

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

NOTICE:
* Do not use excessive force to pry on the hybrid vehicle transmission assembly.
* Do not apply grease either to the splines or input shaft.

3. INSTALL FLYWHEEL HOUSING SIDE COVER

(a) Install the flywheel housing side cover.

4. INSTALL STARTER HOLE INSULATOR

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

Torque : 58 Nm (591 kgf-cm, 43 ft-lbf)

5. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

(a) Install the transmission breather hose with the 2 bolts.

Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

(b) Connect the 4 clamps and clip.

(c) Install a new O-ring.

(d) Coat the O-ring with ATF.

(e) Install the transmission breather plug.

6. INSTALL TRANSMISSION CONTROL SHAFT LEVER

(a) Install the transmission control shaft lever with the nut.

Torque : 16 Nm (163 kgf-cm, 12 ft-lbf)

7. INSTALL OIL COOLER TUBE

(a) Install the oil cooler tube and 4 new gaskets with the 2 bolts.

Torque : 28 Nm (280 kgf-cm, 20 ft-lbf)

(b) Install the oil cooler tube with the bolt.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

8. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY

(a) RH Side:

(1) Install the 3 bolts to the water pipe and hose sub-assembly in the order shown in the illustration.

Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)

(2) Secure the hose with the 2 clips.

(b) LH Side:

(1) Install the 2 bolts to the water pipe and hose sub-assembly in the order shown in the illustration.

Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)

(2) Secure the hose with the clip.

9. INSTALL HYBRID TRANSMISSION MASS DAMPER

(a) Install the hybrid transmission mass damper with the 4 bolts.

Torque : 60 Nm (612 kgf-cm, 44 ft-lbf)

10. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY

(a) Install the rear engine mounting insulator assembly with the 6 bolts.

Torque : 60 Nm (612 kgf-cm, 44 ft-lbf)

11. INSTALL MOTOR CABLE

NOTICE:
When installing the motor cable, minimize bending of the transmission end of the cable.

(a) Align the matchmarks and install the clamps to the motor cable.

(b) Install the 3 O-rings to the terminal cables.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

NOTICE:
* When installing the motor cable, minimize bending of the transmission end of the cable.
* Protect the terminal cables and the installation area from water and foreign objects.
* Make sure that the O-rings do not get caught between any parts.
* Make sure that the tightening torque is between of 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

HINT
To avoid putting too much pressure on the motor cable and bending its end, hold the end of the motor cable in one hand and use the other hand to line the motor cable up and install it against the side of the engine.

(d) Install the 2 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

NOTICE:
Make sure that the tightening torque is between of 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

(e) Install new 3 terminal caps to the hybrid vehicle transmission.

NOTICE:
* Make sure that the O-rings do not get caught between any parts.
* Make sure that the terminals caps are installed securely.

(f) Install the connector cover with the 2 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

NOTICE:
Make sure that the tightening torque is between of 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

12. INSTALL GENERATOR CABLE

NOTICE:
When installing the generator cable, minimize bending of the transmission end of the cable.

(a) Align the matchmarks and install the clamps to the generator cable.

(b) Install the 3 O-rings to the terminal cables.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

NOTICE:
* Protect the terminal cables and the installation area from water or foreign objects.
* Make sure that the O-rings do not get caught between any parts.
* Make sure that the tightening torque is between of 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

HINT
To avoid putting too much pressure on the generator cable and bending its end, hold the end of the generator cable in one hand and use the other hand to line the generator cable up and install it against the side of the engine.

(d) Install the 2 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

NOTICE:
Make sure that the tightening torque is between of 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

(e) Install the new 3 terminal caps to the hybrid vehicle transmission.

NOTICE:
* Be careful that the O-ring does not get caught between the parts.
* Make sure that the terminals caps are installed securely.

(f) Install the connector cover with the 2 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

NOTICE:
Make sure that the tightening torque is between of 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

13. INSTALL GENERATOR CABLE PROTECTOR

(a) Align the matchmarks and install the motor cable protector to the generator cable.

14. INSTALL MOTOR CABLE PROTECTOR

(a) Align the matchmarks and install the motor cable protector to the motor cable.

(b) Connect the generator cable to the motor cable.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

NOTICE:
Make sure that the tightening torque is between of 6.4 and 9.6 N*m (65 and 98 kgf*cm, 57 and 85 in.*lbf).

(d) Align the matchmarks and install the clamp to the motor cable.

NOTICE:
Securely install the clamp.

15. CONNECT WIRE HARNESS

NOTICE:
When installing the motor cable and generator cable, minimize bending of the transmission end of the cable.

(a) Install the wire harness clamps to the hybrid vehicle transmission assembly with the 3 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

NOTICE:
Do not cross or entangle the signal line and power line.

HINT
To avoid putting too much pressure on the motor cable and generator cable and bending its end, hold the end of the motor cable and generator cable in one hand and use the other hand to line the motor cable and generator cable up and install it against the side of the engine.

(b) Connect the connector.

(c) Install the ground cable with the bolt.

Torque : 18 Nm (180 kgf-cm, 13 ft-lbf)

16. CONNECT CONNECTOR

(a) Connect the shift lever position sensor connector, transmission wire connector, transmission revolution sensor connector, engine oil level sensor connector, generator revolution connector, and motor revolution connector.

NOTICE:
Make sure that the wire harness for the oil level sensor is positioned in front of the wire harness of the electrical oil pump.

17. INSTALL ENGINE WITH TRANSMISSION

Installation.

18. PERFORM RESET MEMORY

(a) If the hybrid vehicle transmission assembly is replaced, initialize the learning value of the transmission Programming and Relearning.