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Home >> Lexus >> 2011 >> HS 250h L4-2.4L (2AZ-FXE) Hybrid >> Repair and Diagnosis >> Transmission and Drivetrain >> Continuously Variable Transmission/Transaxle >> Service and Repair >> Removal and Replacement >> Transaxle >> Installation

Installation





P311 HYBRID TRANSMISSION / TRANSAXLE: HYBRID VEHICLE TRANSAXLE: INSTALLATION

1. INSTALL MOTOR CABLE BRACKET

(a) Install the motor cable bracket with the 2 bolts.

Torque : 8.0 Nm (81 kgf-cm, 71 in-lbf)

(b) Connect the 2 clamps.

2. INSTALL AUTOMATIC TRANSMISSION CASE COVER

(a) Install the automatic transmission case cover.

(b) Install the automatic transmission case cover with the 2 bolts and new clip.

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

(c) Connect the 2 clamps.

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 B, C, 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 on the engine.





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

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

Bolt B - Torque : 46 Nm (469 kgf-cm, 34 ft-lbf)

Bolt C - Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

Bolt D - Torque : 44 Nm (449 kgf-cm, 32 ft-lbf)

NOTICE:
* Do not forcibly pry on the hybrid vehicle transaxle assembly.
* Do not apply grease either to the spline or to the input shaft.

Text in Illustration





HINT






7. INSTALL ENGINE MOUNTING BRACKET LH

(a) Install the engine mounting bracket LH with the 4 bolts.





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

NOTICE:
Temporarily tighten bolt A, and then fully tighten the 4 bolts in the order of D, 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 NO. 1 ENGINE MOUNTING INSULATOR Installation

9. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR Installation

10. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY

(a) Install the front crossmember sub-assembly 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)

11. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Installation

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. REMOVE ENGINE HANGER

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





Text in Illustration





17. INSTALL FRONT DRIVE SHAFT LH HOLE SNAP RING Installation

18. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

19. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

20. INSTALL FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY LH Installation

21. INSTALL FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

22. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

23. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

24. CONNECT TIE ROD END SUB-ASSEMBLY LH Installation

25. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

26. INSTALL FRONT SPEED SENSOR LH Installation

27. INSTALL FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

28. INSTALL FRONT AXLE SHAFT NUT LH Installation

29. INSTALL FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

30. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

31. INSTALL FRONT NO. 3 ENGINE UNDER COVER Installation

32. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation

33. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

34. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation

35. INSTALL OIL COOLER INLET TUBE SUB-ASSEMBLY

(a) Temporarily install a new oil cooler inlet tube sub-assembly to the oil cooler tube union.





Text in Illustration





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

Torque : 8.2 Nm (84 kgf-cm, 73 in-lbf)

(c) Using a union nut wrench (17 mm), tighten the oil cooler inlet tube sub-assembly while holding the oil cooler union with a wrench.

Torque : 34 Nm (347 kgf-cm, 25 ft-lbf)

36. INSTALL OIL COOLER UNION SUB-ASSEMBLY

(a) Temporarily install the oil cooler union sub-assembly and oil cooler tube clamp with the bolt.





(b) Install a new gasket to the oil cooler union sub-assembly.





(c) Tighten the union bolt with the oil cooler union sub-assembly stopper pressed against the rib.

Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

Text in Illustration





(d) Tighten the oil cooler tube clamp bolt.

Torque : 8.2 Nm (84 kgf-cm, 73 in-lbf)

37. CONNECT NO. 1 MOTOR COOLING HOSE

(a) Connect the No. 1 motor cooling hose with the clamp.

38. CONNECT NO. 2 MOTOR COOLING HOSE

(a) Connect the No. 2 motor cooling hose with the clamp.

39. INSTALL WIRE HARNESS

(a) Install the heater hose bracket with the bolt.





Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

(b) Install the wire harness bracket with the bolt.





Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

(c) Connect the wire harness with the 4 connectors, 7 clamps and 3 bolts.





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

Bolt B - Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

HINT
When installing clamp A, be sure to align it with the space between the 2 pieces of marking tape on the motor cable.

Text in Illustration





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





(e) Connect the earth wire with the bolt.





Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

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





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

(h) Connect the wire harness with the 3 clamps.





(i) Connect the connector to the hybrid vehicle control ECU with the lock lever.





40. CONNECT INLET HEATER WATER HOSE Installation

41. CONNECT OUTLET HEATER WATER HOSE Installation

42. CONNECT NO. 3 INVERTER COOLING HOSE Installation

43. CONNECT NO. 5 INVERTER COOLING HOSE Installation

44. CONNECT NO. 2 RADIATOR HOSE Installation

45. CONNECT NO. 3 RADIATOR HOSE Installation

46. INSTALL INVERTER BRACKET ASSEMBLY Installation

47. INSTALL AIR CLEANER CASE Installation

48. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

49. INSTALL INVERTER WITH CONVERTER ASSEMBLY Installation

50. CONNECT LOW VOLTAGE CONNECTOR Installation

51. REMOVE CONNECTOR COVER ASSEMBLY Removal

52. CONNECT FRAME WIRE Installation

53. CONNECT AIR CONDITIONING HARNESS ASSEMBLY Installation

54. INSTALL CONNECTOR COVER ASSEMBLY Installation

55. CONNECT WATER HOSE Installation

56. INSTALL INVERTER RESERVE TANK ASSEMBLY Installation

57. CONNECT MOTOR CABLE Installation

58. CONNECT GENERATOR CABLE Installation

59. INSTALL NO. 5 INVERTER BRACKET Installation

60. INSTALL SERVICE PLUG GRIP Installation

61. INSTALL BATTERY SERVICE HOLE COVER Installation

62. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation

63. INSTALL LUGGAGE COMPARTMENT FLOOR MAT Installation

64. ADD HYBRID TRANSAXLE FLUID Procedures

65. ADD COOLANT (for Inverter) Service and Repair

66. ADD COOLANT (for Engine) Service and Repair

67. INSPECT AND ADJUST HYBRID TRANSAXLE FLUID Procedures

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

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

70. INSPECT FOR EXHAUST GAS LEAK

71. INSTALL NO. 2 ENGINE UNDER COVER

72. INSTALL NO. 1 ENGINE UNDER COVER

73. INSTALL ENGINE UNDER COVER

74. INSTALL REAR ENGINE UNDER COVER LH

75. INSTALL REAR ENGINE UNDER COVER RH

76. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

77. INSTALL COWL BODY MOUNTING REINFORCEMENT RH Installation

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

79. INSTALL WATER GUARD PLATE RH Installation

80. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

81. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

82. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

83. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

84. INSTALL FRONT WIPER ARM HEAD CAP Installation

85. INSTALL FRONT WHEELS Installation

86. INSTALL HOOD SUB-ASSEMBLY

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





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

Text in Illustration





(b) Install the 2 stop rings to the hood support assemblies.

(c) Install the 2 hood support assemblies.

(d) Check that the 2 hood support assemblies is engaged in the 2 ball joints and it cannot be pulled out.

(e) Connect the washer hose.

87. INSPECT AND ADJUST HOOD SUB-ASSEMBLY

HINT
Adjustments

88. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

HINT
Front Wheel Alignment

89. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation

90. INSTALL COOL AIR INTAKE DUCT SEAL Installation

91. INSPECT ABS SPEED SENSOR SIGNAL

HINT
Test Mode Procedure.

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