HYBRID TRANSMISSION / TRANSAXLE – HYBRID TRANSAXLE SYSTEM HX–1 HYBRID TRANSAXLE SYSTEM ON-VEHICLE INSPECTION 1. (a) Remove the filler plug. (b) Ensure that the transaxle oil level is within 0 to 5 mm (0 to 0.20 in.) of the filler plug hole. NOTICE: Recheck the transaxle oil level after driving the vehicle when exchanging oil. HINT: Transaxle fluid quantity: 3.8 liters (4.0 US qts, 3.3 Imp. qts.) (c) Check for leaks if the quantity of oil is low. (d) Install the filler plug with a new gasket. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) Filler Plug Drain Plug G030993E01 2. SST SST G030394E01 CHECK TRANSAXLE FLUID LEVEL NOTICE: • Insufficient or excessive amounts of transaxle oil may be the cause of some trouble. • Place the vehicle on level surface. • Use genuine ATF WS. INSPECT OIL PRESSURE NOTICE: Perform the test at normal operating oil temperature 50 to 80°C (122 to 176°F). (a) Lift up the vehicle. (b) Remove the fluid pump cover plug and install SST. SST 09992-00095 (09992-00112, 09992-00271) (c) Set the blower switch to HI. (d) Turn the A/C switch on. (e) Push the power switch with the brake pedal depressed to start the engine (start the hybrid system). (f) Keeping the engine speed of 1,200 rpm, measure the oil pressure. Standard oil pressure: 9.8 kPa (0.1 kgf/cm2, 1.4 psi) or more (g) Install a new O-ring and fluid pump cover plug. Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf) G030396E01 HX HX–2 HYBRID TRANSMISSION / TRANSAXLE – HYBRID TRANSAXLE SYSTEM 3. Key Slot INSPECT SHIFT LEVER (a) Inspect the shift lever operation with the hybrid system operating. (1) Carry the key into the indoor electrical key oscillator detection area or insert the key in the key slot. (2) Turn the power switch ON (READY ON) while depressing the brake pedal. Check that the gear changes according to the shift operation pattern. If the check result is abnormal, replace the shift lever assembly. HINT: The shift operation pattern in power switch ON (READY ON) (when the vehicle is stopped) is shown below. Turn the power switch ON C097702E02 Power Mode Operation P R N D B Shift Lever Operation Hybrid System in operation (driving possible) HX P Position Switch Operation C130921E01 (b) Turn the power switch OFF when the vehicle is stopped. Power Switch G021872E01 HX–3 HYBRID TRANSMISSION / TRANSAXLE – HYBRID TRANSAXLE SYSTEM (c) Inspect the shift lever operation with the power switch's power mode ON (IG). (1) Carry the key into the indoor electrical key oscillator detection area or insert the key in the key slot. Key Slot G030999E01 (d) Turn the power switch ON (IG) without depressing the brake pedal. HINT: The power switch's power mode changes between OFF, ON (ACC) and ON (IG) each time the power switch is pressed. (e) Check that the gear changes according to the shift operation pattern. If the check result is not as specified, replace the shift lever assembly. HINT: The shift operation pattern with the power switch's power mode ON (IG) is shown below. Power Switch Turn the power switch ON without depressing the brake pedal. G030998E02 Power Mode Operation Power switch ON (IG) (Driving not possible) Shift Lever Operation HX P R N D B P Position Switch Operation C130922E01 HX–4 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM ELECTRONIC SHIFT LEVER SYSTEM PRECAUTION 1. NOTICE FOR INITIALIZATION When the cable of the negative (-) battery terminal is disconnected, initialize the following systems after the cable is reconnected. System Name See procedure Power Window Control System IN-32 2. NOTICE FOR HYBRID SYSTEM ACTIVATION • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. HX HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–5 PARTS LOCATION P POSITION SWITCH (P POSITION SWITCH INDICATOR LIGHT) COMBINATION METER - MASTER WARNING LIGHT MULTI-DISPLAY HYBRID VEHICLE CONTROL ECU POWER SOURCE CONTROL ECU TRANSMISSION CONTROL ECU ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK - TRANSAXLE PARKING LOCK CONTROL RELAY (Marking: P CON) - INTEGRATION RELAY (unit B: IGCT RELAY) - P CON MTR H-FUSE - P CON MAIN FUSE - HEV FUSE DLC3 SELECTOR LEVER HYBRID VEHICLE TRANSAXLE HX SHIFT CONTROL ACTUATOR C126757E01 HX–6 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM SYSTEM DIAGRAM : BEAN Selector Lever : CAN Multi-display P Position Switch : AVC-LAN Skid Control ECU P Position Switch Hybrid Vehicle Control ECU Indicator Light Gateway ECU Vehicle Information - Vehicle Speed Signal - Stop Light Switch Signal Power Source Control ECU Skid Control Actuator HX Parking Lock Motor Transmission Control ECU Rotation Angle Sensor Combination Meter Transponder Key ECU Certification ECU Multiplex Network Body ECU C126758E01 Input and output signals of each ECU Transmitting ECU (transmitter) Receiving ECU Signals Communication method Skid Control ECU Transmission Control ECU PKB switch signal CAN, BEAN HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM Transmitting ECU (transmitter) Receiving ECU Signals Communication method Power Source Control ECU Transmission Control ECU Power off preparation signal BEAN Main Body ECU Transmission Control ECU • • Power switch signal ACC switch signal BEAN Transmission Control ECU Power Source Control ECU • • P position state signal Transmission control ECU trouble condition signal Auto P cancel signal Non-P position state signal Auto P permit signal BEAN • • • Transmission Control ECU Multi-display Transmission control ECU trouble signal AVC-LAN, BEAN Transmission Control ECU Combination Meter Transmission control ECU trouble signal BEAN Transmission Control ECU Transponder Key Amplifier • • BEAN Transmission Control ECU Certification ECU P position state signal P position state signal Key condition signal HX–7 BEAN HX HX–8 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM SYSTEM DESCRIPTION 1. 2. SYSTEM DESCRIPTION The electronic shift lever system electrically controls the parking lock mechanism by using the actuator. The transmission control ECU controls the shift control actuator, and also controls the entire system based on information from the hybrid vehicle control ECU. The transmission control ECU detects DTCs when there are any malfunctions in the system, and informs the driver of the malfunction by illuminating the P position switch indicator light and master warning light, and indicating an error message on the multi-display. FUNCTION OF EACH COMPONENT Parts name Function Shift Control Actuator • • • Transmission Control ECU • • HX Composed of the parking lock motor and the rotation angle sensor. The motor is activated by electric current from the transmission control ECU. Motor rotation is reduced by the cycloid reduction mechanism in the shift control actuator and then output. The rotation angle sensor detects the motor rotation angle with the 3 Hall ICs. This ECU activates the shift control actuator based on signals from the hybrid vehicle control ECU and the power source control ECU. This ECU controls the application timing of current to the parking lock motor based on signals from the rotation angle sensor. Parking Lock Mechanism The parking lock pawl rotates according to the movement of the parking lock rod when the parking lock motor rotates, and engages with the parking gear on the transaxle side, causing the parking lock mechanism to lock or unlock. Hybrid Vehicle Control ECU This ECU sends a P lock or P unlock demand signal to the transmission control ECU based on information from the selector lever and the P position switch. Power Source Control ECU This ECU sends a signal with power off information to the transmission control ECU. The transmission control ECU then sends the signal to the hybrid vehicle control ECU. P Position Switch Indicator Light This light comes on/goes off to indicate the P lock/unlock status and blinks to indicate a malfunction in the electronic shift lever system. Combination Meter A malfunction in the transmission control ECU is indicated by the illumination of the master warning light on the combination meter. Multi-display A malfunction in the transmission control ECU is indicated on the multi-display. HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM 3. P Position Switch “ON” Switch Operation Signal HX–9 OPERATION DESCRIPTION (a) Operation to switch to the P position: (1) When the P position switch is turned on to activate parking lock, a signal is sent to the hybrid vehicle control ECU. (2) The hybrid vehicle control ECU determines whether "P lock" is possible or not based on this signal and other vehicle information. (3) If the hybrid vehicle control ECU determines that "P lock" is possible, it sends a "P lock" operation demand signal to the transmission control ECU. Transmission Control ECU “P Lock” Operation Signal Hybrid Vehicle Control ECU Vehicle Speed Signal C126759E01 HX HX–10 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM P Position Switch Indicator Light (4) After receiving the signal, the transmission control ECU activates the shift control actuator in order to lock the parking lock mechanism, and turns on the P position switch indicator light. ON Demand Signal Skid Control Actuator “P Lock” Switch Control Rotation Angle Sensor Signal Transmission Control ECU C126760E01 HX Cycloid Reduction Mechanism Output Shaft Internal Gear External Gear Center of Eccentric Adapter Bearing Eccentric Adapter Center of Motor Input Shaft C126761E01 (5) The transmission control ECU controls motor rotation angle based on signals from the rotation angle sensor in the shift control actuator. HINT: In the cycloid reduction mechanism, the output shaft is linked to the external gear. Together, they rotate only a single tooth when the eccentric adapter, which is linked to the motor, rotates once. Driving force is increased in this way so that the parking lock mechanism can be switched even when high output is required for parking on a hill, etc. HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–11 (b) Operation to switch to a non-P position: (1) When the hybrid system is started (the vehicle is ready to be driven) and the selector lever is moved to the R, N, or the D position with the brake pedal depressed, a signal is sent to the hybrid vehicle control ECU. (2) This signal is then sent from the hybrid vehicle control ECU to the transmission control ECU as a "P lock release" operation demand signal. Selector Lever Selector Lever Operation Signal Transmission Control ECU “P Lock Release” Operation Signal Hybrid Vehicle Control ECU Stop Light Switch Signal C126762E01 HX HX–12 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM P Position Switch Indicator Light OFF Demand Signal Shift Control Actuator “P Lock Release” Switch Control Rotation Angle Sensor Signal Transmission Control ECU C126763E01 HX 4. (3) After receiving the signal, the transmission control ECU activates the shift control actuator in order to unlock the parking lock mechanism, and turns off the P position switch indicator light. (4) The transmission control ECU controls motor rotation angle based on signals from the rotation angle sensor in the shift control actuator. SHIFT POSITION CHANGE FUNCTION (a) The electronic shift lever system comprehensively determines vehicle conditions and changes the shift position, as shown in the following chart, by cooperating with the shift control function of the hybrid system (except when the reject function, described later, is in operation). HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–13 (b) Other than indicated in the following chart, when the power switch is turned OFF with the vehicle stopped, the shift position is automatically changed to the P position. Power Status ON (ACC)* (The vehicle cannot be driven.) Operation Selector lever operation Unable to change the shift position P position switch operation ON (IG)* (The vehicle cannot be driven.) Selector lever operation P position switch operation Selector lever operation The hybrid system is started. (The vehicle can be driven.) HX P position switch operation *: The vehicle cannot be driven because the hybrid system has not been started. : Current position : Positions to which the shift position can be changed C126764E01 HX–14 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM 5. HX REJECT FUNCTION (a) In the electronic shift lever system, there may be a situation in which a shift change cannot be done for safety reasons. When attempting to move the selector lever in such a situation, the system sounds a reject buzzer inside the meter and changes the shift position as shown in the following table. Shift operation which causes reject function to operate Shift position after rejection Shifting from the P position without depressing the brake pedal Held in the P position Shifting to the P position while driving Changed to the N position Shifting between forward and reverse positions while driving Changed to the N position Shifting to the B position from the position other than D Changed to the N position HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–15 HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the electronic shift lever system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. NEXT 3 CHECK COMMUNICATION FUNCTION OF MULTIPLEX COMMUNICATION SYSTEM (BEAN)* (a) Use the intelligent tester to check if the Multiplex Communication System (MPX) is functioning normally. Result Result Proceed to MPX DTC is not output A MPX DTC is output B B Go to MULTIPLEX COMMUNICATION SYSTEM A 4 CHECK COMMUNICATION FUNCTION OF CAN COMMUNICATION SYSTEM* (a) Use the intelligent tester to check if the CAN communication system is functioning normally. Result Result Proceed to CAN DTC is not output A CAN DTC is output B B A Go to CAN COMMUNICATION SYSTEM HX HX–16 5 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM CHECK FOR DTC* (a) Check for DTCs and note any codes that are output. (b) Delete the DTC. (c) Recheck for DTCs. Based on the DTCs output above, try to force output of the electronic shift lever system DTC by simulating the operation indicated by the DTC. Result Result Proceed to DTC is not output A DTC is output B B Go to step 8 A 6 PROBLEM SYMPTOMS TABLE Refer to the problem symptoms table (see page HX-15). Result Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B Go to step 8 A 7 OVERALL ANALYSIS AND TROUBLESHOOTING* (a) DATA LIST / ACTIVE TEST (see page HX-19) (b) Terminals of ECU (see page HX-15) HX NEXT 8 NEXT END REPAIR OR REPLACE HX–17 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. Electronic shift lever system Symptom P position switch indicator light does not come on. P position switch indicator light does not go off. Suspected area See page 1. P position switch indicator light circuit HX-54 2. Transmission control ECU HX-15 1. P position switch indicator light circuit HX-54 2. Transmission control ECU HX-15 HX HX–18 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM TERMINALS OF ECU 1. CHECK TRANSMISSION CONTROL ECU HINT: Inspect the connectors from the back side while the connector is connected. T4 12 11 10 9 8 7 6 5 4 26 25 24 23 22 21 20 3 2 1 19 18 17 16 15 14 13 B119765E02 HX Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition +B (T4-1) - E1 (T4-15) L - W-B Power source Power switch ON (IG) 9 to 14 V E02 (T4-2) - Body ground W-B - Body ground Ground Always Below 1 V E01 (T4-3) - Body ground W-B - Body ground Ground Always Below 1 V RZ1 (T4-4) - E2 (T4-16) L-P Rotation angle sensor signal Power switch ON (IG) 4 to 5.5 V RB (T4-5) - E2 (T4-16) GR - P Rotation angle sensor signal Power switch ON (IG) 4 to 5.5 V RA (T4-6) - E2 (T4-16) LG - P Rotation angle sensor signal Power switch ON (IG) 4 to 5.5 V PCON (T4-7) - E1 (T4-15) LG - W-B Communication bus Power switch ON (IG) Pulse generation (see wave form 1) PPOS (T4-8) - E1 (T4-15) W - W-B Communication bus Power switch ON (IG) Pulse generation (see wave form 2) IND (T4-9) - E1 (T4-15) R - W-B P position switch indicator light P position switch ON Below 1 V MWA (T4-10) - E1 (T4-15) W - W-B Parking lock motor Power switch ON (IG) 9 to 14 V MVA (T4-11) - E1 (T4-15) R - W-B Parking lock motor Power switch ON (IG) 9 to 14 V MUA (T4-12) - E1 (T4-15) B - W-B Parking lock motor Power switch ON (IG) 9 to 14 V BATT (T4-13) - E1 (T4-15) L - W-B Power source (RAM) Always 9 to 14 V BMA (T4-14) - E1 (T4-15) B - W-B P CON relay Power switch ON (IG) 9 to 14 V E1 (T4-15) - Body ground W-B - Body ground Ground Always Below 1 V E2 (T4-16) - Body ground P - Body ground Ground Always Below 1 V VC (T4-17) - E2 (T4-16) O-P Power source (Rotation angle sensor) Power switch ON (IG) 4 to 5.5 V MPX2 (T4-18) - E1 (T415) B - W-B Multiplex communication Power switch OFF Power switch ON (IG) Below 1 V Pulse generation MPX1 (T4-19) - E1 (T415) GR - W-B Multiplex communication Power switch OFF Power switch ON (IG) Below 1 V Pulse generation SIL (T4-20) - E1 (T4-15) W - W-B Diagnosis tester communication Power switch ON (IG) 8 V or higher HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–19 (a) Using an oscilloscope, check the waveform 1. Waveform 1 (Reference) Waveform 1 Item Content Symbols (Terminal No.) P CON (T4-7) - E1 (T4-15) Tool setting 5 V/DIV., 20 msec./DIV. Condition Power switch ON (IG) GND C126766E01 (b) Using an oscilloscope, check the waveform 2. Waveform 2 (Reference) Waveform 2 Item Content Symbols (Terminal No.) PPOS (T4-8) - E1 (T4-15) Tool setting 5 V/DIV., 20 msec./DIV. Condition Power switch ON (IG) GND C126767E01 HX HX–20 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DIAGNOSIS SYSTEM SG CG 1. DESCRIPTION (a) Electronic shift lever system data and the Diagnostic Trouble Codes (DTCs) can be read in the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform repairs. 2. CHECK DLC3 The vehicle uses ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CANH SIL BAT CANL H100769E19 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 Ω SG (5) - Body ground Signal ground Always Below 1 Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Power Switch OFF* 54 to 69 Ω CANH (6) - Battery positive (+) HIGH-level CAN bus line Power Switch OFF* 1 MΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Power Switch OFF* 1 kΩ or higher CANL (14) - Battery positive (+) LOW-level CAN bus line Power Switch OFF* 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Power Switch OFF* 1 kΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the displays indicators that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. HX Intelligent Tester DLC3 CAN VIM A082795E09 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–21 DTC CHECK / CLEAR 1. Intelligent Tester DLC3 2. CAN VIM A082795E09 CHECK DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Read the DTC by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC (a) Connect the intelligent tester to the DLC3. (b) Turn the power switch ON (IG). (c) Erase the DTC by following the directions on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. HX HX–22 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM FREEZE FRAME DATA 1. HX CHECK FREEZE FRAME DATA (a) The vehicle status, stored during system operation or at the time of an error code detection, can be displayed by the intelligent tester. (b) Only one record of freeze frame data is stored and the freeze frame data generated during system operation are updated whenever the vehicle status is changed. After storing the DTC, the freeze frame data is not updated. Tester Display Measurement Item Reference Value SHFT POS P Shift position display (P) ON or OFF SHFT POS N-P Shift position display (not P) ON or OFF MAS CAUTION Master caution display DISP or NONDISP PSW INDICATOR PSW indicator mode OFF, ON, FAST, or SLOW U VOL VAL U phase voltage value min: 0 V, max: 20 V V VOL VAL V phase voltage value min: 0 V, max: 20 V W VOL VAL W phase voltage value min: 0 V, max: 20 V BATT VOL VAL BATT voltage value min: 0 V, max: 20 V IG (+B) VOL VAL IG (+B) voltage value min: 0 V, max: 20 V P SPLY OFF SIG Power supply off preparation request signal ON or OFF LRN LOCK POS Completion of learning lock position OK or NG LRN UNLOCK POS Completion of learning unlock position OK or NG TRIP CNTR Number of trip counter after learning min: 0, max: 65535 MTR MAIN RELAY Main relay for motor drive ON or OFF ELCTRCL KEY SIG Signal of electrical key condition ON or OFF CURRENT U U phase current-carrying status ON or OFF CURRENT V V phase current-carrying status ON or OFF CURRENT W W phase current-carrying status ON or OFF U VOL U phase voltage status ON or OFF V VOL V phase voltage status ON or OFF W VOL W phase voltage status ON or OFF BATT VOL BATT voltage status ON or OFF IG VOL IG (+B) phase voltage status ON or OFF ACC SIG ACC condition signal ON or OFF INIT CNTRL Initial drive control completed OK or NG DTCT LOCK POS Completion of detecting lock position OK or NG DTCT UNLOCK POS Completion of detecting unlock position OK or NG SHFT RANGE P/Not P movable shift range SET or UNSET MAIN RELAY Main relay NORMAL or ABNOML VHCL COND Vehicle condition STOP or MOVE FAIL RANK Fail rank min: 0, max: 255 ECU TYPE Type of ECU min: 0, max: 65535 DETAIL INFO1 Detailed information 1 Failure information is displayed in hexadecimal DETAIL INFO2 Detailed information 2 Failure information is displayed in hexadecimal DETAIL INFO3 Detailed information 3 Failure information is displayed in hexadecimal HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–23 FAIL-SAFE CHART If the transmission control ECU detects a malfunction, the failsafe functions shown in the table below are activated. DTC No. Fail-safe Function Problem Symptoms C2300 C2301 Only the P position release operation is possible and the shift control actuator is activated. • C2303 - The battery is dead. C2304 C2305 C2306 The transaxle parking lock control relay is turned off. The parking lock mechanism cannot be switched. C2307 The transaxle parking lock control relay is turned off. • • • The shift position is not indicated on the meter. Although the shift position is indicated on the meter, the vehicle cannot be driven. The shift position is not indicated on the meter. Although the shift position is indicated on the meter, the vehicle cannot be driven. C2311 - The parking lock mechanism cannot be switched. C2312 - The hybrid system does not start up. C2318 - The parking lock mechanism cannot be switched on a hill. HX HX–24 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and press the intelligent tester main switch on. (c) Read the DATA LIST by following the directions on the tester screen. Transmission control ECU HX Item Measurement Item / Range (Display) Normal Condition Diagnostic Note SHFT POS P Shift position display (P) / ON or OFF ON: Parking lock is in P position OFF: Parking lock is in non-P position - SHFT POS N-P Shift position display (not P) / ON or OFF ON: Parking lock is in non-P position OFF: Parking lock is in P position - MAS CAUTION Master caution display / DISP or NONDISP DISP: Malfunction occurs in this system NONDISP: Malfunction does not occur in this system - PSW INDICATOR PSW indicator mode / OFF, ON, FAST, or SLOW OFF: Parking lock is in non-P position ON: Parking lock is in P position FAST: Actuator takes long time to switch between the P position and non-P position SLOW: Malfunction occurs in this system - U VOL VAL U phase voltage value / min: 0 V, max: 20 V Actual U phase voltage 9 to 14 V - V VOL VAL V phase voltage value / min: 0 V, max: 20 V Actual V phase voltage 9 to 14 V - W VOL VAL W phase voltage value / min: 0 V, max: 20 V Actual W phase voltage 9 to 14 V - BATT VOL VAL BATT voltage value / min: 0 V, max: 20 V Actual power supply voltage 9 to 14 V - IG (+B) VOL VAL IG (+B) voltage value / min: 0 V, max: 20 V Actual power supply voltage 9 to 14 V - P SPLY OFF SIG Power supply off preparation request signal / ON or OFF ON: Power is turned off by power source control ECU after receiving power switch OFF signal OFF: Any other condition - LRN LOCK POS Completion of learning lock position / OK or NG OK: Lock position learning is complete NG: Lock position learning is not complete - LRN UNLOCK POS Completion of learning unlock position / OK or NG OK: Unlock position learning is complete NG: Unlock position learning is not complete - TRIP CNTR Number of trip counter after learning / min: 0, max: 65535 Actual number of trip counter Reset the trip counter after 1,000 times HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM Item Measurement Item / Range (Display) Normal Condition Diagnostic Note MTR MAIN RELAY Main relay for motor drive / ON or OFF ON: Motor drive main relay on OFF: Motor drive main relay off - ELCTRCL KEY SIG Signal of electrical key condition / ON or OFF ON: Electrical key is recognized OFF: Electrical key is not recognized - #CODE Number of diagnosis code / min: 0, max: 255 Actual number of diagnosis code - CURRENT U U phase current-carrying status / ON or OFF ON: U phase current flows OFF: U phase current does not flow - CURRENT V V phase current-carrying status / ON or OFF ON: V phase current flows OFF: V phase current does not flow - CURRENT W W phase current-carrying status / ON or OFF ON: W phase current flows OFF: W phase current does not flow - U VOL U phase voltage status / ON or OFF ON: U phase voltage is 6 V or more OFF: U phase voltage is less than 6V - V VOL V phase voltage status / ON or OFF ON: V phase voltage is 6 V or more OFF: V phase voltage is less than 6V - W VOL W phase voltage status / ON or OFF ON: W phase voltage is 6 V or more OFF: W phase voltage is less than 6 V - BATT VOL BATT voltage status / ON or OFF ON: BATT voltage is more than 10 V OFF: BATT voltage is 10 V or less - IG VOL IG (+B) phase voltage status / ON or OFF ON: +B voltage is more than 10 V OFF: +B voltage is 10 V or less - ACC SIG ACC condition signal / ON or OFF ON: ACC condition signal is normal OFF: ACC condition signal is interrupted - INIT CNTRL Initial drive control completed / OK or NG OK: Initial drive control is complete NG: Initial drive control is not complete - DTCT LOCK POS Completion of detecting lock position / OK or NG OK: Detection of lock position is complete NG: Detection of lock position is not complete - DTCT UNLOCK POS Completion of detecting unlock position / OK or NG OK: Detection of unlock position is complete NG: Detection of unlock position is not complete - SHFT RANGE P/Not P movable shift range / SET or UNSET SET: P/Not P movable shift range is set UNSET: P/Not P movable shift range is unset - MAIN RELAY Main relay / NORMAL or ABNOML NORMAL: Main relay is normal ABNOML: Main relay is fault - VHCL COND Vehicle condition / STOP or MOVE STOP: Vehicle is stopped MOVE: Vehicle is running - ECU TYPE Type of ECU / min: 0, max: 65535 Actual type of ECU - HX–25 HX HX–26 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DIAGNOSTIC TROUBLE CODE CHART If a trouble code is displayed during the DTC check, check the circuit listed for that code in the table below and proceed to the appropriate page. HINT: • When the DTC C2300, C2301, C2304, C2305, C2306, C2307, C2311 and C2312 are detected, DTC P3102 indicating the electronic shift lever system malfunctions are detected for the hybrid system as well. Because of this, the hybrid system DTCs must be cleared after clearing the electronic shift lever system DTCs. • Remove the P CON MAIN fuse to erase DTCs C2300, C2301, C2303, C2304, C2305, C2306 and C2307 because they cannot be erased with the intelligent tester. • When a DTC is detected, the master warning light comes on and an error message is indicated on the multi-display. • The indicator blinks quickly when it takes a long time to switch between the P position status and the P position release status. DTC No. HX Detection Item Trouble Area P Position Switch Indicator Light Condition HINT See page C2300 ACT System Malfunction - Shift control actuator - Transaxle parking lock control relay - Transmission control ECU - Wire harness or connector Blinks slowly If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-24 C2301 Shift Changing Time Malfunction - Shift control actuator - Transmission control ECU Blinks slowly If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-31 C2303 Relay Malfunction (+B Short) - Transaxle parking lock control relay - Transmission control ECU - Wire harness or connector Normal - P position status: the P position switch indicator light is on. - P position release status: the P position switch indicator light is off. If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-32 C2304 Open or Short Circuit in "U" Phase - Shift control actuator - Transmission control ECU - Transaxle parking lock control relay - Wire harness or connector Blinks slowly If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-35 C2305 Open or Short Circuit in "V" Phase - Shift control actuator - Transmission control ECU - Transaxle parking lock control relay - Wire harness or connector Blinks slowly If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-35 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–27 HINT See page Blinks slowly If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-35 - Transmission control ECU - Wire harness or connector - Parking lock motor (Shift control actuator) Blinks slowly If DTC C2318 is output simultaneously, perform troubleshooting for DTC C2318 first. HX-40 Open or Short Circuit in BATT - P CON MAIN fuse - Transmission control ECU - Wire harness or connector Normal - P position status: the P position switch indicator light is on. - P position release status: the P position switch indicator light is off. - HX-42 C2311 HV Communication Line Malfunction - Transmission control ECU - Hybrid vehicle control ECU - Wire harness or connector Blinks slowly - HX-44 C2312 Power Source Control ECU Communication Line Malfunction - Transmission control ECU - Power source control ECU Normal - P position status: the P position switch indicator light is on. - P position release status: the P position switch indicator light is off. - HX-47 C2315 HV System Malfunction - Hybrid vehicle control ECU - P position switch - Transmission control ECU - Wire harness or connector Normal - P position status: the P position switch indicator light is on. - P position release status: the P position switch indicator light is off. - HX-50 Low Voltage Error (Power Supply Malfunction) - HEV fuse - IGCT relay - Wire harness or connector - Auxiliary battery Normal - P position status: the P position switch indicator light is on. - P position release status: the P position switch indicator light is off. - DTC No. Detection Item Trouble Area C2306 Open or Short Circuit in "W" Phase - Shift control actuator - Transmission control ECU - Transaxle parking lock control relay - Wire harness or connector C2307 Power Source Malfunction C2310 C2318 P Position Switch Indicator Light Condition HX HX-52 HX–28 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2300 ACT System Malfunction DESCRIPTION The shift control actuator consists of the parking lock motor and the rotation angle sensor. The transmission control ECU receives a P position switch signal from the hybrid vehicle control ECU and activates the parking lock motor by controlling current, causing the parking lock mechanism to switch. The transmission control ECU also detects the rotor rotation angle through the rotation angle sensor to control timing of current application to the coils. The transmission control ECU outputs this DTC when it detects a malfunction in the shift control actuator system. HX DTC No. DTC Detection Condition Trouble Area C2300 When both conditions below are met: • Power switch ON (IG). • There is an open or short circuit in the transaxle parking lock control relay and/or shift control actuator, or an internal abnormality in the shift control actuator. • • • • Shift control actuator Transaxle parking lock control relay (P CON Relay) Transmission control ECU Wire harness or connector HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–29 WIRING DIAGRAM Shift Control Actuator Assembly Transmission Control ECU RE2 E2 RZ1 RZ1 RB RB RA RA RVC VC MWA MWA V Phase MVA MVA W Phase U Phase MGNA MUA MUA P CON P CON MTR HX BMA E02 MAIN Auxiliary Battery E01 C126768E01 HX–30 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM INSPECTION PROCEDURE 1 CHECK OTHER DTC OUTPUT (BESIDES DTC C2300) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester on. (d) Read the DTCs. Result Display (DTC output) Proceed to No output A C2304, C2305, C2306 and C2318 B HINT: If any other codes besides C2300 are output, perform the troubleshooting for those DTCs first. B REPAIR CIRCUIT INDICATED BY OUTPUT CODE A 2 CHECK TRANSMISSION CONTROL ECU (VC, RA, RB, RZ1 VOLTAGE) RA RB (a) Measure the voltage of the ECU connector. Standard voltage RZ1 Tester Connection T4 E2 HX VC F044944E02 NG Condition Specified Condition T4-4 (RZ1) - T4-16 (E2) Power switch ON (IG) 4 to 5.5 V T4-5 (RB) - T4-16 (E2) Power switch ON (IG) 4 to 5.5 V T4-6 (RA) - T4-16 (E2) Power switch ON (IG) 4 to 5.5 V T4-17 (VC) - T4-16 (E2) Power switch ON (IG) 4 to 5.5 V OK Go to step 5 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM 3 HX–31 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - SHIFT CONTROL ACTUATOR) (a) Disconnect the T4 ECU connector. (b) Disconnect the S1 actuator connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transmission Control ECU RZ1 RB RA T4 E2 VC Shift Control Actuator RB Tester Connection Specified Condition T4-17 (VC) - S1-9 (RVC) Below 1 Ω T4-5 (RB) - S1-3 (RB) Below 1 Ω T4-6 (RA) - S1-5 (RA) Below 1 Ω T4-4 (RZ1) - S1-4 (RZ1) Below 1 Ω T4-16 (E2) - S1-8 (RE2) Below 1 Ω T4-4 (RZ1) - Body ground 10 kΩ or higher T4-5 (RB) - Body ground 10 kΩ or higher T4-6 (RA) - Body ground 10 kΩ or higher T4-17 (VC) - Body ground 10 kΩ or higher NG RZ1 RA REPAIR OR REPLACE HARNESS AND CONNECTOR S1 RE2 RVC C126765E01 OK 4 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - BODY GROUND) (a) Disconnect the T4 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side E02 E01 Tester Connection (Symbols) Specified Condition T4-2 (E02) - Body ground Below 1 Ω T4-3 (E01) - Body ground Below 1 Ω T4 OK B118155E11 Go to step 11 HX HX–32 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM NG REPAIR OR REPLACE HARNESS AND CONNECTOR 5 CHECK WIRE HARNESS (SHIFT CONTROL ACTUATOR - BATTERY) (a) Disconnect the S1 actuator connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side S1 MGNA Tester Connection Condition Specified Condition S1-2 (MGNA) - Body ground Power switch ON (IG) 9 to 14 V NG Go to step 7 C126783E01 OK 6 READ VALUE OF INTELLIGENT TESTER (U, V, W VOLTAGE) (a) Check the DATA LIST for proper functioning of the shift control actuator. Shift control actuator HX Item Measurement Item / Range (Display) Normal Condition Diagnostic Note U VOL VAL U phase voltage value / min: 0 V, max: 20 V Actual U phase voltage 9 to 14 V - V VOL VAL V phase voltage value / min: 0 V, max: 20 V Actual V phase voltage 9 to 14 V - W VOL VAL W phase voltage value / min: 0 V, max: 20 V Actual W phase voltage 9 to 14 V - Standard voltage: 9 to 14 V NG Go to step 10 OK REPLACE TRANSMISSION CONTROL ECU 7 INSPECT FUSE (P CON MTR) (a) Remove the P CON MTR H-fuse from the engine room relay block. (b) Measure the resistance of the H-fuse. Standard resistance: Below 1 Ω HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM NG HX–33 INSPECT FOR SHORT IN ALL COMPONENTS CONNECTED TO FUSE AND REPAIR OR REPLACE THEM IF NEEDED, AND REPLACE H-FUSE OK 8 INSPECT TRANSAXLE PARKING LOCK CONTROL RELAY (Marking: P CON) (a) Remove the P CON relay from the engine room relay block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) B112776E02 NG REPLACE TRANSAXLE PARKING LOCK CONTROL RELAY OK 9 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - BODY GROUND) (a) Disconnect the T4 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side T4 Tester Connection Specified Condition T4-14 (BMA) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU - BODY GROUND) BMA B118155E12 OK REPAIR OR REPLACE HARNESS AND CONNECTOR (SHIFT CONTROL ACTUATOR - BATTERY) HX HX–34 10 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - SHIFT CONTROL ACTUATOR) (a) Disconnect the T4 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Transmission Control ECU MWA MVA MUA T4 Tester Connection Specified Condition T4-10 (MWA) - S1-1 (MWA) Below 1 Ω T4-11 (MVA) - S1-6 (MVA) Below 1 Ω T4-12 (MUA) - S1-7 (MUA) Below 1 Ω T4-10 (MWA) - Body ground 10 kΩ or higher T4-11 (MVA) - Body ground 10 kΩ or higher T4-12 (MUA) - Body ground 10 kΩ or higher NG Shift Control Actuator REPAIR OR REPLACE HARNESS AND CONNECTOR MWA S1 MVA MUA C126765E02 OK HX 11 INSPECT SHIFT CONTROL ACTUATOR G030192E01 (a) Remove the 3 bolts and transmission case cover. (b) Remove the 3 bolts. (c) Slightly pull the shift control actuator from the hybrid vehicle transaxle so that the shift control actuator can be turned. (d) Turn the shift control actuator. OK: The shift control actuator turns smoothly. HINT: There may be an internal actuator abnormality if the actuator does not turn smoothly. NG OK REPLACE TRANSMISSION CONTROL ECU REPLACE SHIFT CONTROL ACTUATOR HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2301 HX–35 Shift Changing Time Malfunction DESCRIPTION The transmission control ECU receives a P position switch signal from the hybrid vehicle control ECU and then activates the shift control actuator. At the same time, the transmission control ECU detects the length of time it takes for the parking lock mechanism to switch. The transmission control ECU outputs this DTC when this length of time is longer than specification. DTC No. DTC Detection Condition Trouble Area C2301 When both conditions below are met: • Power switch ON (IG). • There is an internal abnormality in the shift control actuator for 2 seconds or more (the parking lock motor runs idle). • • Shift control actuator Transmission control ECU INSPECTION PROCEDURE 1 CHECK SHIFT CONTROL ACTUATOR G030192E01 (a) Remove the 3 bolts and transmission case cover. (b) Remove the 3 bolts. (c) Slightly pull the shift control actuator from the hybrid vehicle transaxle so that the shift control actuator can be turned. (d) Turn the shift control actuator. OK: The shift control actuator turns smoothly. HINT: There may be an internal actuator abnormality if the actuator does not turn smoothly. NG OK REPLACE TRANSMISSION CONTROL ECU REPLACE SHIFT CONTROL ACTUATOR HX HX–36 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2303 Relay Malfunction (+B Short) DESCRIPTION The transaxle parking lock control relay (Marking: P CON) is activated by output voltage from the transmission control ECU and supplies power to the shift control actuator. The transmission control ECU outputs this DTC when it detects a malfunction in the transaxle parking lock control relay. DTC No. DTC Detection Condition Trouble Area C2303 When both conditions below are met: • The transaxle parking lock control relay is off. • Voltage of the transmission control ECU terminals MUA, MVA, and MWA is 6 V or more for 64 msec. or more. • • • Transaxle parking lock control relay (P CON relay) Transmission control ECU Wire harness or connector WIRING DIAGRAM Shift Control Actuator Transmission Control ECU MWA V Phase MWA MVA MVA MGNA W Phase U Phase MUA MUA P CON HX P CON MTR BMA MAIN Auxiliary Battery C126769E01 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–37 INSPECTION PROCEDURE 1 INSPECT TRANSAXLE PARKING LOCK CONTROL RELAY (Marking: P CON) (a) Remove the P CON relay from the engine room relay block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) B112776E02 NG REPLACE TRANSAXLE PARKING LOCK CONTROL RELAY OK 2 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - CONTROL RELAY) (a) Disconnect the T4 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side T4 Tester Connection Specified Condition T4-14 (BMA) - Body ground Below 1 V NG HX BMA B118155E12 OK REPAIR OR REPLACE HARNESS AND CONNECTOR HX–38 3 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - ACTUATOR) (a) Disconnect the T4 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side Transmission Control ECU T4 Tester Connection Specified Condition T4-10 (MWA) - Body ground Below 1 V T4-11 (MVA) - Body ground Below 1 V T4-12 (MUA) - Body ground Below 1 V NG MWA MVA REPAIR OR REPLACE HARNESS AND CONNECTOR MUA B118155E18 OK 4 CHECK WIRE HARNESS (SHIFT CONTROL ACTUATOR - CONTROL RELAY) (a) Disconnect the S1 actuator connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side S1 MGNA Tester Connection Specified Condition S1-2 (MGNA) - Body ground Below 1 V NG HX C126783E01 OK REPLACE TRANSMISSION CONTROL ECU REPAIR OR REPLACE HARNESS AND CONNECTOR HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2304 Open or Short Circuit in "U" Phase DTC C2305 Open or Short Circuit in "V" Phase DTC C2306 Open or Short Circuit in "W" Phase HX–39 DESCRIPTION The shift control actuator consists of the parking lock motor and the rotation angle sensor. The transmission control ECU receives a P position switch signal from the hybrid vehicle control ECU and activates the parking lock motor by controlling current, causing the parking lock mechanism to switch. The transmission control ECU outputs this DTC when it detects a malfunction in the parking lock motor system. DTC No. DTC Detection Condition Trouble Area C2304 When both conditions below are met: • Power switch ON (IG) (battery voltage is 8 V or more). • Voltage of transmission control ECU terminal MUA is 6 V or less for 1 second or more. • • • When both conditions below are met: • Power switch ON (IG) (battery voltage is 8 V or more). • Voltage of transmission control ECU terminal MVA is 6 V or less for 1 second or more. • • • When both conditions below are met: • Power switch ON (IG) (battery voltage is 8 V or more). • Voltage of transmission control ECU terminal MWA is 6 V or less for 1 second or more. • • • C2305 C2306 • • • Shift control actuator Transmission control ECU Transaxle parking lock control relay (P CON Relay) Wire harness or connector Shift control actuator Transmission control ECU Transaxle parking lock control relay (P CON Relay) Wire harness or connector Shift control actuator Transmission control ECU Transaxle parking lock control relay (P CON Relay) Wire harness or connector HX HX–40 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM WIRING DIAGRAM Shift Control Actuator Transmission Control ECU MWA V Phase MWA MVA MVA MGNA W Phase U Phase MUA MUA P CON P CON MTR BMA MAIN Auxiliary Battery C126769E01 HX INSPECTION PROCEDURE 1 CHECK FOR DTC (a) (b) (c) (d) Connect the intelligent tester to the DLC3. Turn the power switch ON (IG). Turn the intelligent tester on. Read the DTCs. Result Display (DTC output) Proceed to C2304, C2305 and C2306 are detected simultaneously A C2304, C2305 and C2306 are not detected simultaneously B HINT: • When DTCs C2304, C2305 and C2306 are detected simultaneously, there may be an open or short circuit between the shift control actuator and the battery. HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–41 • When DTCs C2304, C2305 and C2306 are not detected simultaneously, there may be an open or short circuit in the shift control actuator or between the actuator and the ECU. B Go to step 6 A 2 CHECK WIRE HARNESS (SHIFT CONTROL ACTUATOR - BATTERY) (a) Disconnect the S1 actuator connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side S1 MGNA Tester Connection Condition Specified Condition S1-2 (MGNA) - Body ground Power switch ON (IG) 9 to 14 V OK Go to step 6 C126783E01 NG 3 INSPECT FUSE (P CON MTR FUSE) (a) Remove the P CON MTR H-fuse from the engine room relay block. (b) Measure the resistance of the H-fuse. Standard resistance: Below 1 Ω NG INSPECT FOR SHORT IN ALL COMPONENTS CONNECTED TO FUSE AND REPAIR OR REPLACE THEM IF NEEDED, AND REPLACE H-FUSE OK 4 INSPECT TRANSAXLE PARKING LOCK CONTROL RELAY (Marking: P CON RELAY) (a) Remove the P CON relay from the engine room relay block. (b) Measure the resistance of the relay. Standard resistance Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage is applied to terminals 1 and 2) B112776E02 NG REPLACE TRANSAXLE PARKING LOCK CONTROL RELAY HX HX–42 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM OK 5 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - BODY GROUND) (a) Disconnect the T4 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side T4 Tester Connection Specified Condition T4-14 (BMA) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR (TRANSMISSION CONTROL ECU - BODY GROUND) BMA B118155E12 OK REPAIR OR REPLACE HARNESS AND CONNECTOR (SHIFT CONTROL ACTUATOR - BATTERY) 6 READ VALUE OF INTELLIGENT TESTER (U, V, W VOLTAGE) (a) Check the DATA LIST for proper functioning of the shift control actuator. Shift control actuator HX Item Measurement Item / Range (Display) Normal Condition Diagnostic Note U VOL VAL U phase voltage value / min: 0 V, max: 20 V Actual U phase voltage 9 to 14 V - V VOL VAL V phase voltage value / min: 0 V, max: 20 V Actual V phase voltage 9 to 14 V - W VOL VAL W phase voltage value/min: 0 V, max: 20 V Actual W phase voltage 9 to 14 V - Standard voltage: 9 to 14 V OK NG REPLACE TRANSMISSION CONTROL ECU HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM 7 HX–43 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - SHIFT CONTROL ACTUATOR) Wire Harness Side Transmission Control ECU MWA MVA MUA T4 (a) Disconnect the T4 ECU connector. (b) Disconnect the S1 actuator connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition T4-10 (MWA) - S1-1 (MWA) Below 1 Ω T4-11 (MVA) - S1-6 (MVA) Below 1 Ω T4-12 (MUA) - S1-7 (MUA) Below 1 Ω T4-10 (MWA) - Body ground 10 kΩ or higher T4-11 (MVA) - Body ground 10 kΩ or higher T4-12 (MUA) - Body ground 10 kΩ or higher NG Shift Control Actuator REPAIR OR REPLACE HARNESS AND CONNECTOR MWA S1 MVA MUA C126765E02 OK REPLACE SHIFT CONTROL ACTUATOR HX HX–44 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2307 Power Source Malfunction DESCRIPTION The shift control actuator consists of the parking lock motor and the rotation angle sensor. The transmission control ECU receives a P position switch signal from the hybrid vehicle control ECU and activates the parking lock motor by controlling current, causing the parking lock mechanism to switch. The transmission control ECU outputs this DTC when it detects a malfunction in the parking lock motor system and/or the ground circuit. DTC No. DTC Detection Condition Trouble Area C2307 When both conditions below are met: • Power switch ON (IG) • The parking lock motor current is 50 A or more, or there is an open in the terminal E1 circuit of the transmission control ECU for 0.1 seconds or more. • • • Transmission control ECU Wire harness or connector Parking lock motor (Shift control actuator) WIRING DIAGRAM Shift Control Actuator Transmission Control ECU MWA V Phase MWA MVA MVA MGNA W Phase U Phase MUA MUA HX P CON P CON MTR BMA MAIN Auxiliary Battery E1 C126770E01 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–45 INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - BODY GROUND) (a) Disconnect the T4 ECU connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side T4 Tester Connection Specified Condition T4-15 (E1) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR E1 B118155E16 OK 2 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - BODY GROUND) (a) Measure the voltage of the wire harness and connector. Standard voltage Wire Harness Side Tester Connection T4 MWA MVA MUA Specified Condition T4-10 (MWA) - Body ground Below 1 V T4-11 (MVA) - Body ground Below 1 V T4-12 (MUA) - Body ground Below 1 V NG B118155E13 OK REPLACE TRANSMISSION CONTROL ECU REPAIR OR REPLACE HARNESS AND CONNECTOR HX HX–46 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2310 Open or Short Circuit in BATT DESCRIPTION The auxiliary battery voltage is constantly applied to terminal BATT. The terminal BATT voltage is used to power the transmission control ECU memory. The transmission control ECU outputs this DTC when it detects a malfunction related to terminal BATT. DTC No. DTC Detection Condition Trouble Area C2310 When both conditions below are met: • Power switch ON (IG) • Terminal BATT voltage of the transmission control ECU is 10 V or less for 1 second or more. • • • P CON MAIN fuse Transmission control ECU Wire harness or connector HINT: When there is an open or short in the BATT circuit, information on the actuator position ("P position" or "non-P position") stored in the ECU is cleared every time the power switch is turned OFF. Therefore, the ECU works to recognize the position each time the power switch is turned ON (IG). As a result, the time from when the power switch is turned ON (IG) until "READY ON" is indicated may become longer than normal. WIRING DIAGRAM Transmission Control ECU MAIN P CON MAIN BATT Auxiliary Battery HX C126771E01 INSPECTION PROCEDURE 1 INSPECT FUSE (P CON MAIN) (a) Remove the P CON MAIN fuse from the engine room relay block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω P CON MAIN Fuse NG F047675E01 INSPECT FOR SHORT IN ALL COMPONENTS CONNECTED TO FUSE AND REPAIR OR REPLACE THEM IF NEEDED, AND REPLACE FUSE HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–47 OK 2 READ VALUE OF INTELLIGENT TESTER (BATT VOLTAGE) (a) Check the DATA LIST for proper functioning of the transmission control ECU. Transmission control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note BATT VOL VAL BATT voltage value / min: 0 V, max: 20 V Actual power supply voltage 9 to 14 V - Standard voltage: 9 to 14 V OK REPLACE TRANSMISSION CONTROL ECU NG 3 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - P CON MAIN FUSE) (a) Disconnect the T4 ECU connector. (b) Remove the P CON fuse from the engine room relay block. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transmission Control ECU T4 BATT Tester Connection Specified Condition T4-13 (BATT) - 2 (P CON MAIN Fuse) Below 1 Ω T4-13 (BATT) - Body ground 10 kΩ or higher Engine Room Relay Block NG P CON MAIN Fuse REPAIR OR REPLACE HARNESS AND CONNECTOR C126778E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR (P CON MAIN FUSE - BATTERY) HX HX–48 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2311 HV Communication Line Malfunction DESCRIPTION The transmission control ECU receives a P position switch signal from the hybrid vehicle control ECU and activates the parking lock motor by controlling current, causing the parking lock mechanism to switch. The transmission control ECU outputs this DTC when it detects a communication error between the hybrid vehicle control ECU and the transmission control ECU. DTC No. DTC Detection Condition Trouble Area C2311 When both conditions below are met: • Power switch ON (IG) • Signals from the hybrid control ECU cannot be received, or there is a problem with a pulse signal from the hybrid vehicle control ECU for 1 second or more. • • • Transmission control ECU Hybrid vehicle control ECU Wire harness or connector WIRING DIAGRAM Hybrid Vehicle Control ECU Transmission Control ECU PCON PCON C126772E01 HX HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–49 INSPECTION PROCEDURE 1 CHECK TRANSMISSION CONTROL ECU (PCON SIGNAL) (a) Check output waveform. (1) Turn the power switch ON (IG). (2) Using an oscilloscope, check the output waveform of the transmission control ECU connector. OK: The output waveform appears as shown in the illustration. PCON T4 121110 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14 13 E1 Normal Signal Waveform Item Contents Symbols (Terminal No.) PCON (T4-7) - E1 (T4-15) Tool setting 5 V/DIV., 20 msec./DIV. Vehicle condition Power switch ON (IG) OK REPLACE TRANSMISSION CONTROL ECU GND C136043E01 NG HX HX–50 2 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM CHECK WIRE HARNESS (HYBRID VEHICLE CONTROL ECU - TRANSMISSION CONTROL ECU) (a) Disconnect the T4 and H17 ECU connectors. (b) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transmission Control ECU T4 PCON Tester Connection (Symbols) Specified Condition T4-7 (PCON) - H17-9 (PCON) Below 1 Ω T4-7 (PCON) - Body ground 10 kΩ or higher NG Hybrid Vehicle Control ECU H17 PCON C126779E01 OK HX REPLACE HYBRID VEHICLE CONTROL ECU REPAIR OR REPLACE HARNESS AND CONNECTOR HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2312 HX–51 Power Source Control ECU Communication Line Malfunction DESCRIPTION The transmission control ECU receives power switch condition signals (OFF / ON (ACC) / ON (IG)) from the power source control ECU. The transmission control ECU outputs this DTC when it does not receive the signals. DTC No. DTC Detection Condition Trouble Area C2312 When both conditions below are met: • Power switch ON (IG) • Signals from the power source control ECU cannot be received for 10 seconds or more. • • Transmission control ECU Power source control ECU HX HX–52 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM WIRING DIAGRAM Transmission Control ECU Certification ECU MPX1 MPX1 Transponder key ECU MPX2 MPX2 IGCT P/I HEV +B Hybrid Vehicle Control ECU MAIN MREL E1 HX C126773E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (P SPLY OFF SIGNAL) (a) Check the DATA LIST for proper functioning of the transmission control ECU. Transmission control ECU Item Measurement Item / Range (Display) Normal Condition Diagnostic Note P SPLY OFF SIG Power supply off preparation request signal / ON or OFF ON: Power is turned off by power source control ECU after receiving power switch OFF signal OFF: Any other condition - HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–53 OK: ON is displayed. NG REPLACE POWER SOURCE CONTROL ECU OK REPLACE TRANSMISSION CONTROL ECU HX HX–54 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2315 HV System Malfunction DESCRIPTION The transmission control ECU receives a P position switch signal from the hybrid vehicle control ECU and activates the parking lock motor by controlling current, causing the parking lock mechanism to switch. When the hybrid control ECU detects a malfunction with the P position switch or P position signal, it sends an information signal to the transmission control ECU. After receiving this signal, the transmission control ECU outputs this DTC. DTC No. DTC Detection Condition Trouble Area C2315 When both conditions below are met: • Power switch ON (IG) • A malfunction signal from the hybrid control ECU is received for 1 second or more. • • • • Hybrid vehicle control ECU P position switch Transmission control ECU Wire harness or connector WIRING DIAGRAM Hybrid Vehicle Control ECU Transmission Control ECU PCON PCON C126772E01 INSPECTION PROCEDURE 1 CHECK OTHER DTC OUTPUT (BESIDES DTC C2315) HX (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester on. (d) Read the DTCs. Result Result Proceed to No output A P0851-579, P0852-580, P3102-597, 598 and 599 B HINT: • DTCs P0851 and P0852 indicate P position switch malfunctions. DTC P0851-579 indicates "short to ground" and P0852-580 indicates "open" or "short to +B". • DTC P3102 indicates a P position signal error. DTC P3102-597 indicates "short to ground", P3102-598 indicates "short to +B", and P3102-599 indicates "duty ratio error". HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM B HX–55 REPAIR CIRCUIT INDICATED BY OUTPUT CODE A REPLACE HYBRID VEHICLE CONTROL ECU HX HX–56 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM DTC C2318 Low Voltage Error (Power Supply Malfunction) DESCRIPTION The auxiliary battery voltage is applied to terminal +B when the power switch is ON (IG). The transmission control ECU outputs this DTC when the input voltage drops. DTC No. DTC Detection Condition Trouble area C2318 When both conditions below are met: • Power switch ON (IG) • Terminal +B voltage of the transmission control ECU is 9.3 V or less for 1 second or more. • • • • HEV fuse IGCT relay Wire harness or connector Auxiliary battery WIRING DIAGRAM Hybrid Vehicle Control ECU Transmission Control ECU IGCT P/I HEV +B MREL MAIN Auxiliary Battery HX C126774E01 INSPECTION PROCEDURE 1 INSPECT FUSE (HEV) (a) Remove the HEV fuse from the engine room relay block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG HEV Fuse F044949E01 INSPECT FOR SHORT IN ALL COMPONENTS CONNECTED TO FUSE AND REPAIR OR REPLACE THEM IF NEEDED, AND REPLACE FUSE HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM HX–57 OK 2 CHECK OTHER DTC OUTPUT (BESIDE C2318) (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG). (c) Turn the intelligent tester on. (d) Read the DTCs. Result Result Proceed to No output A P3110-223 B HINT: DTC P3110 indicates HV main relay malfunction. DTC P3110-223 indicates "IGCT relay malfunction". B REPAIR CIRCUIT INDICATED BY OUTPUT CODE A 3 READ VALUE OF INTELLIGENT TESTER (IG (+B) VOLTAGE) (a) Check the DATA LIST for proper functioning of the transmission control ECU. Transmission control ECU Item Measurement Item / Range (Display) Normal Condition IG (+B) VOL VAL IG (+B) voltage value / min: 0 V, max: 20 V Actual power supply voltage 9 to 14 V Standard voltage: 9 to 14 V OK REPLACE TRANSMISSION CONTROL ECU NG REPAIR OR REPLACE HARNESS AND CONNECTOR (ENGINE ROOM RELAY BLOCK AND JUNCTION BLOCK - TRANSMISSION CONTROL ECU) HX HX–58 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM "P" Position Switch Indicator Light Circuit DESCRIPTION The parking lock switch indicator light comes on or goes off to indicate the on/off status of the P position switch and blinks to indicate malfunction conditions of the system. WIRING DIAGRAM Transmission Control ECU P Position Switch MAIN P CON MAIN IND Auxiliary Battery C126775E01 INSPECTION PROCEDURE 1 CHECK INDICATOR LIGHT (a) Inspect the indicator light condition by operating the P position switch. Result HX Condition Proceed to Indicator light does not go off. A Indicator light does not come on. B B A Go to step 3 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM 2 HX–59 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - P POSITION SWITCH) (a) Disconnect the T4 ECU connector. (b) Disconnect the M11 switch connector. (c) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side Transmission Control ECU T4 Tester Connection Specified Condition T4-9 (IND) - Body ground 10 kΩ or higher NG REPAIR OR REPLACE HARNESS AND CONNECTOR IND B118155E17 OK REPLACE TRANSMISSION CONTROL ECU 3 INSPECT FUSE (P CON MAIN) (a) Remove the P CON MAIN fuse from the engine room relay block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω P CON MAIN Fuse NG F047675E01 OK INSPECT FOR SHORT IN ALL COMPONENTS CONNECTED TO FUSE AND REPAIR OR REPLACE THEM IF NEEDED, AND REPLACE FUSE HX HX–60 4 HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - BATTERY) (a) Disconnect the T4 ECU connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side Transmission Control ECU T4 Tester Connection Specified Condition T4-9 (IND) - Body ground 9 to 14 V OK REPLACE TRANSMISSION CONTROL ECU IND B118155E17 NG 5 CHECK WIRE HARNESS (TRANSMISSION CONTROL ECU - P POSITION SWITCH) (a) Disconnect the T4 ECU connector. (b) Disconnect the M11 switch connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Transmission Control ECU T4 IND Tester Connection Specified Condition T4-9 (IND) - M11-6 Below 1 Ω NG HX P Position Switch M11 C126780E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR HYBRID TRANSMISSION / TRANSAXLE – ELECTRONIC SHIFT LEVER SYSTEM 6 HX–61 CHECK WIRE HARNESS (P POSITION SWITCH - BATTERY) (a) Disconnect the M11 switch connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side M11 Tester Connection Specified Condition M11-5 - Body ground 9 to 14 V OK REPLACE P POSITION SWITCH C126781E01 NG REPAIR OR REPLACE HARNESS AND CONNECTOR HX HX–58 HYBRID TRANSMISSION / TRANSAXLE – COOLANT COOLANT REPLACEMENT 1. REMOVE ENGINE UNDER COVER LH 2. REMOVE ENGINE UNDER COVER RH 3. DRAIN COOLANT (a) Remove the transaxle-side reserve tank cap. CAUTION: Do not remove the reserve tank cap while the engine is hot. (b) Remove the plug shown in the illustration and drain the coolant into a container. (c) Install the plug with a new gasket. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) C098375E01 4. ADD COOLANT (a) Loosen the bleeder plug shown in the illustration and connect a hose. NOTICE: Insert one end of the hose into the bleeder tank. C098376E01 HX C098377E01 (b) Add coolant until the level of coolant in the hose attached to the bleeder tank reaches the same level as the FULL line of the reserve tank. NOTICE: Add genuine Toyota Super LLC coolant. (c) Close the bleeder plug. (d) Turn the power switch ON (IG) and run the water pump for approximately 20 seconds. (e) Turn the power switch OFF. (1*) (f) Loosen the bleeder plug and bleed the air from the transaxle. (g) Add coolant into the bleeder tank. (*3) (h) Repeat the steps *1, *2 and *3. Standard: Water pump noise becomes softer and coolant circulation in reserve tank improves. Coolant system air bleeding is complete HYBRID TRANSMISSION / TRANSAXLE – COOLANT (i) (j) 5. HX–59 HINT: If air remains in the coolant system, the water pump noise becomes louder and the coolant circulation in the reserve tank becomes worse. Turn the power switch ON (IG) and run the water pump for approximately 5 minutes after completing air bleeding of the coolant system. NOTICE: Ensure that the bleeder plug is closed. Add coolant until the reserve tank is filled up to the FULL mark. CHECK FOR ENGINE COOLANT LEAKAGE (a) Check for engine coolant leakage (see page CO-9). C098378E01 HX HX–60 HYBRID TRANSMISSION / TRANSAXLE – SHIFT CONTROL ACTUATOR SHIFT CONTROL ACTUATOR HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS TRANSMISSION CASE COVER 16 (163, 12) HX 7.0 (71, 62 in.*lbf) N*m (kgf*cm, ft.*lbf) : Specified torque SHIFT CONTROL ACTUATOR ASSEMBLY C129403E01 HYBRID TRANSMISSION / TRANSAXLE – SHIFT CONTROL ACTUATOR HX–61 REMOVAL 1. REMOVE SHIFT CONTROL ACTUATOR ASSEMBLY (a) Disconnect the connector. (b) Remove the 3 bolts and transmission case cover from the hybrid vehicle transaxle. C098379E02 (c) Remove the 3 bolts and shift control actuator from the hybrid vehicle transaxle. HX Z035712E01 INSTALLATION 1. G030526E01 INSTALL SHIFT CONTROL ACTUATOR ASSEMBLY (a) Apply a small amount of ATF WS to the O-ring. HX–62 HYBRID TRANSMISSION / TRANSAXLE – SHIFT CONTROL ACTUATOR (b) Install the shift control actuator to the hybrid vehicle transaxle with the 3 bolts. Torque: 16 N*m (163 kgf*cm, 12 ft.*lbf) Z035712E01 (c) Install the transmission case cover to the hybrid vehicle transaxle with the 3 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) (d) Connect the connector. HX C098379E02 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY HX–63 HYBRID VEHICLE TRANSAXLE ASSEMBLY HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS 11 (112, 8) INVERTER COVER INVERTER RESERVOIR TANK 21 (214, 15) 8.0 (82, 71 in.*lbf) INVERTER WITH CONVERTER ASSEMBLY HX ENGINE UNDER COVER RH ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque C129404E01 HX–64 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY 80 (816, 59) 8.0 (82, 71 in.*lbf) NO. 3 ENGINE MOUNTING BRACKET 8.0 (82, 71 in.*lbf) 62 (630, 46) GASKET EXHAUST PIPE ASSEMBLY x6 33 (337, 24) HYBRID VEHICLE TRANSAXLE ASSEMBLY INTERMEDIATE SHAFT FRONT DRIVE SHAFT RH 49 (357, 26) FRONT DRIVE SHAFT LH CLIP 49 (500, 36) COLUMN HOLE COVER 216 (2,203, 159) CLIP HX 49 (500, 24) 74 (755, 55) 74 (755, 55) TORQUE ROD 157 (1,601, 116) 100 (1,020, 74) 89 (908, 65) 60 (612, 44) N*m (kgf*cm, ft.*lbf) : Specified torque 113 (1,152, 83) FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Non-reusable part C129405E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY HX–65 ON-VEHICLE INSPECTION 1. INSPECT SPEED SENSOR (RESOLVER) A B A077571E01 Connector B MCS GSN MRF MCSG MSNG MRFG (a) Using an ohmmeter, measure the resistance between the terminals. A077568E05 Connector A GRF GSN GCS Standard resistance Tester Connection GRFG GSNG GCSG A077568E04 Specified Condition A1 (GCS) - A4 (GCSG) 12.6 to 16.8 Ω A2 (GSN) - A5 (GSNG) 12.6 to 16.8 Ω A3 (GRF) - A6 (GRFG) 7.65 to 10.2 Ω B1 (MRF) - B4 (MRFG) 7.65 to 10.2 Ω B2 (MSN) - B5 (MSNG) 12.6 to 16.8 Ω B3 (MCS) - B6 (MCSG) 12.6 to 16.8 Ω All of terminals above - Transaxle housing 10 kΩ or higher If the results are not as specified, replace the hybrid vehicle transaxle assembly. HX HX–66 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY 2. INSPECT TEMPERATURE SENSOR C A083656E02 Connector C OMT MMT OMTG MMTG (a) Using an ohmmeter, measure the resistance between the terminals. A077568E06 HX Resistance kΩ Standard resistance 120 110 100 90 80 70 60 50 40 30 20 10 0 10 (50)15 (59) 20 (68) 25 (77) 30 (86) 35 (95) Sensor Temperature °C (°F) A125180E01 Tester Connection Specified Condition C1 (MMT) - C4 (MMTG) 87.3 to 110.5 kΩ at 10°C (50°F) 23.8 to 28.5 kΩ at 40°C (104°F) C3 (OMT) - C6 (OMTG) 87.3 to 110.5 kΩ at 10°C (50°F) 23.8 to 28.5 kΩ at 40°C (104°F) All of terminals above - Transaxle housing 1 MΩ or higher HINT: The standard varies according to the sensor temperature. If the results are not as specified, replace the hybrid vehicle transaxle assembly. HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY HX–67 REMOVAL CAUTION: • When working on the high voltage systems, always wear insulated gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SERVICE PLUG GRIP (a) Remove the service plug grip (see page HB-153). 3. REMOVE FRONT WHEEL 4. REMOVE ENGINE UNDER COVER LH 5. REMOVE ENGINE UNDER COVER RH 6. DRAIN COOLANT (a) Drain the coolant (see page HX-58). 7. DRAIN TRANSAXLE OIL (a) Drain the transaxle oil (see page HX-1). 8. REMOVE HOOD SUB-ASSEMBLY (a) Remove the hood (see page ED-2). 9. REMOVE FRONT WIPER ARM LH (a) Remove the front wiper arm LH (see page WW-13). 10. REMOVE FRONT WIPER ARM RH (a) Remove the front wiper arm RH (see page WW-13). 11. REMOVE COWL TOP FRONT PANEL SUBASSEMBLY OUTER (a) Remove the cowl top front panel (see page WW13). 12. REMOVE INVERTER WITH CONVERTER ASSEMBLY (a) Remove the inverter with converter (see page HV533). 13. REMOVE AIR CLEANER ASSEMBLY (a) Remove the air cleaner (see page ES-450). HX HX–68 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY 14. DISCONNECT WIRE HARNESS (a) Disconnect the 3 connectors shown in the illustration and the clamp. Front G030089E01 (b) Disconnect the 2 clamps shown in the illustration. Front C098456E01 (c) Disconnect the connector. (d) Remove the 3 bolts and transmission case cover from the hybrid vehicle transaxle. HX C098379E02 (e) Disconnect the 2 clamps. Front Z035713E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY (f) HX–69 Remove the bolt and ground wire. Front C098457E01 15. DISCONNECT NO. 4 INVERTER COOLING HOSE (a) Remove the 4 clamps and disconnect the 3 hoses. 16. REMOVE FRONT DRIVE SHAFT ASSEMBLY (a) Remove the front drive shaft (see page DS-4). 17. DISCONNECT EXHAUST PIPE ASSEMBLY (a) Disconnect the exhaust pipe (see page EX-2). Clamp Front Clamp 18. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (See page EM-96) C097764E01 No. 1 Engine Hanger Front No. 2 Engine Hanger Rear D025372E01 19. SUSPEND ENGINE ASSEMBLY (a) Disconnect the 2 PCV hoses. (b) Install the No. 1 and No. 2 engine hangers in the correct direction. Parts No.: No. 1 engine hanger: 12281-22021 No. 2 engine hanger: 12281-15040 Bolt: 91512-B1016 Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) (c) Attach an engine chain hoist to the engine hangers. CAUTION: Do not attempt to hang the engine by hooking the chain to any other parts. 20. SUPPORT HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Using a transmission jack, support the hybrid vehicle transaxle. 21. DISCONNECT NO. 3 ENGINE MOUNTING BRACKET (a) Remove the nut and disconnect the engine mounting bracket from the engine mounting insulator. Front C098372E01 HX HX–70 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY Front 22. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Remove the 2 bolts, starter cover and housing side cover. G030261E01 (b) Remove the 6 bolts and hybrid vehicle transaxle. NOTICE: To avoid damage to the knock pin, do not pry the connecting portion of the HV transaxle and the engine. Pin Pin G031001E01 23. REMOVE NO. 6 INVERTER COOLING HOSE (a) Remove the clamp and inverter cooling hose. Front C098448E01 HX 24. REMOVE NO. 3 ENGINE MOUNTING BRACKET (a) Remove the 3 bolts and engine mounting bracket. Front C098374E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY HX–71 (b) Remove the 6 bolts shown in the illustration and clamp. C098449E01 HX HX–72 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY INSTALLATION CAUTION: • When working on the high voltage systems, always wear insulated gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. HX INSTALL NO. 3 ENGINE MOUNTING BRACKET (a) Install the clump in the position shown in the illustration with the 6 bolts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) C098449E01 (b) Install the No. 3 engine mounting bracket with the 3 bolts. Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) Front C098374E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY HX–73 2. INSTALL NO. 6 INVERTER COOLING HOSE (a) Connect the inverter cooling hose and install the clamp. 3. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Install the hybrid vehicle transaxle with the 6 bolts. Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) NOTICE: • Ensure that the knock pin is installed on the engine side. • Place the HV transaxle in a horizontal position and Align the knock pin and its hole. Then tighten the 6 bolts in the positions shown in the illustration. Front C098448E01 Pin Pin G031001E01 (b) Install the housing side cover and starter cover with the 2 bolts. Torque: 32 N*m (326 kgf*cm, 23 ft.*lbf) Front G030261E01 4. 5. REMOVE NO. 1 ENGINE HANGER (a) Remove the bolt and engine hanger. 6. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (See page EM-106) 7. CONNECT EXHAUST PIPE ASSEMBLY (a) Connect the exhaust pipe (see page EX-3). 8. INSTALL FRONT DRIVE SHAFT ASSEMBLY (a) Install the front drive shaft (see page DS-15). Front C098372E01 INSTALL NO. 3 ENGINE MOUNTING BRACKET (a) Install the engine mounting bracket to the engine mounting insulator with the nut. Torque: 80 N*m (816 kgf*cm, 59 ft.*lbf) HX HX–74 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY 9. CONNECT NO. 4 INVERTER COOLING HOSE (a) Connect the 3 hoses with the 4 clamps. Clamp Clamp Front C097764E01 10. CONNECT CONNECTOR (a) Connect the ground wire with the bolt. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) Front C098457E01 (b) Connect the 2 clamps. Front Z035713E01 (c) Install the transmission case cover to the hybrid vehicle transaxle with the 3 bolts. Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) (d) Connect the connector. HX C098379E02 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY HX–75 (e) Connect the clamps in the 2 locations shown in the illustration. Front C098456E01 (f) Connect the clamp and the 3 connectors shown in the illustration. 11. INSTALL AIR CLEANER ASSEMBLY (a) Install the air cleaner (see page ES-453). 12. INSTALL INVERTER WITH CONVERTER ASSEMBLY (a) Install with inverter converter (see page HV-535). Front G030089E01 13. INSTALL COWL TOP FRONT PANEL SUBASSEMBLY OUTER (a) Install the cowl top front panel (see page WW-15). 14. INSTALL FRONT WIPER ARM RH (a) Install the front wiper arm (see page WW-16). 15. INSTALL FRONT WIPER ARM LH (a) Install the front wiper arm (see page WW-16). 16. INSTALL HOOD SUB-ASSEMBLY (a) Install the hood (see page ED-4). 17. ADJUST HOOD SUB-ASSEMBLY (a) Adjust the hood (see page ED-4). 18. INSTALL ENGINE UNDER COVER RH 19. INSTALL ENGINE UNDER COVER LH 20. INSTALL FRONT WHEEL 21. INSTALL SERVICE PLUG GRIP (a) Install the service plug grip (see page HB-154). 22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 23. ADD TRANSAXLE OIL Fluid type: Toyota genuine ATF WS Standard capacity: 3.8 liters (4.0 US qts, 3.3 Imp. qts) 24. INSPECT TRANSAXLE OIL (a) Inspect the transaxle oil (see page HX-1). 25. ADD COOLANT (a) Add the coolant (see page HX-58). 26. CHECK FOR ENGINE COOLANT LEAKAGE (a) Check for engine coolant leakage (see page CO-9). HX HX–76 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE ASSEMBLY 27. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (a) Inspect and adjust the front wheel alignment (see page SP-2). 28. PERFORM CALIBRATION (a) Perform calibration (see page PS-13). 29. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HX HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–75 HYBRID VEHICLE TRANSAXLE UNIT HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS MOTOR WATER JACKET COVER NO. 3 ENGINE MOUNTING BRACKET SHIFT CONTROL ACTUATOR ASSEMBLY 5.5 (56, 49 in.*lbf) TRANSMISSION CASE COVER 52 (530, 38) 7.0 (71, 62 in.*lbf) 39 (398, 29) 5.5 (56, 49 in.*lbf) SET PLUG 16 (160, 12) GASKET PARKING SHAFT COVER O-RING 7.9 (81, 70 in.*lbf) MANUAL DETENT SPRING MANUAL DETENT SPRING COVER TRANSMISSION OIL STRAINER 9.8 (100, 86 in.*lbf) 25 (255, 18) 5.5 (56, 49 in.*lbf) x8 39 (398, 29) SET PLUG GASKET PARKING COVER 5.8 (59, 51 in.*lbf) 55 (561, 41) HX HYBRID TRANSAXLE OIL SEAL LH SCREW PLUG MOTOR STATOR WIRING HARNESS CONNECTOR 5.8 (59, 51 in.*lbf) MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR x5 5.7 (58, 50 in.*lbf) OIL PUMP DRIVE SHAFT N*m (kgf*cm, ft.*lbf) : Specified torque DRIVEN ROTOR Non-reusable part Apply ATF WS Apply MP grease O-RING DRIVE ROTOR OIL PUMP COVER O-RING 7.4 (75, 65 in.*lbf) OIL PUMP COVER PLUG C129406E01 HX–76 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT BREATHER PLUG POWER CABLE COVER HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL HYBRID TRANSAXLE OIL SEAL RH 15 (155, 11) TRANSAXLE HOUSING TUBE CONNECTOR x 13 13 (133, 10) SCREW PLUG 25 (255, 18) COUNTER DRIVEN GEAR SUB-ASSEMBLY OUTER RACE DIFFERENTIAL CASE ASSEMBLY 4.8 (49, 42 in.*lbf) OUTER RACE 5.8 (59, 51 in.*lbf) 39 (400, 29) GASKET GENERATOR MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR SET PLUG SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR SHIM CHAIN SHIM THRUST NEEDLE ROLLER BEARING HX TRANSMISSION DRIVE SPROCKET SUB-ASSEMBLY THRUST BEARING RACE PLANETARY RING GEAR 5.8 (59, 51 in.*lbf) 8.5 (87, 75 in.*lbf) NEEDLE ROLLER BEARING 5.5 (56, 49 in.*lbf) INPUT SHAFT ASSEMBLY THRUST BEARING RACE N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part PLANETARY RING GEAR FLANGE SHIM GENERATOR CABLE Apply ATF WS Apply MP grease C129407E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–77 DISASSEMBLY CAUTION: • When working on the high voltage systems, always wear insulated gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Remove the hybrid vehicle transaxle (see page HX66). 2. REMOVE HYBRID VEHICLE GENERATOR ASSEMBLY (a) Install the 2 engine hangers in the positions shown in the illustration. HINT: • Engine hanger: 12281-67070, S1228-11781 • Bolt: 91642-81045, 91642-81265 • Nut: 90178-10001, 90179-12147 (b) Using an engine sling device and chain block, set the transaxle with the generator side facing upward. NOTICE: • Place the transaxle on wooden blocks or equivalent. • Fix the transaxle so that no excessive force is applied to the cable. (c) Remove the drain plug. C098482E01 (d) Remove the 21 bolts shown in the illustration. HINT: • 13 bolts on the generator side. • 8 bolts on the motor side. C099316E01 HX HX–78 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT (e) Disconnect the motor and generator by inserting a flat-head screwdriver in the position shown and prying the two apart. NOTICE: Be careful not to damage the two faces of each part. (f) Using an engine sling device and chain block, raise the generator. HINT: Raise the generator approximately 30 to 40 mm (1.18 to 1.57 in.). C099317E01 (g) Apply protective tape to the head of a flat-head screwdriver and use it to hold down the chain with input shaft while removing the generator. C099318E01 HX Counter Driven Gear 3. REMOVE COUNTER DRIVEN GEAR SUB-ASSEMBLY (a) Remove the counter driven gear from the HV motor. 4. REMOVE DIFFERENTIAL CASE ASSEMBLY (a) Remove the differential case from the HV motor. C099319E02 Differential Case C069292E02 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT 5. Thrust Bearing Race HX–79 REMOVE TRANSMISSION DRIVE SPROCKET SUBASSEMBLY (a) Remove the thrust bearing race, thrust needle roller bearing and No. 1 thrust bearing race. HINT: The thrust bearing race may be attached to the generator side. Thrust Needle Roller Bearing C069408E01 (b) Remove the drive sprocket and chain. Chain C069293E01 6. REMOVE INPUT SHAFT ASSEMBLY (a) Remove the input shaft. 7. REMOVE PLANETARY RING GEAR (a) Remove the thrust bearing race, thrust needle roller bearing and No. 1 thrust bearing race. HINT: The thrust bearing race may be attached to the input shaft side. Input Shaft C069294E01 Thrust Needle Roller Bearing Thrust Bearing Race C069295E01 (b) Remove the planetary ring rear. Planetary Ring Gear C069296E01 HX HX–80 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT Planetary Ring Gear Flange 8. REMOVE PLANETARY RING GEAR FLANGE (a) Remove the planetary ring gear flange and shim. 9. REMOVE SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR (a) Using a plastic-faced hammer, tap the motor case and remove the counter drive gear and shim. HINT: Remove the counter drive gear while pulling it vertically. Shim G030634E01 Sprocket Driven and Counter Drive Gear Shim C099320E02 10. FIX TRANSMISSION OIL STRAINER (a) Remove the bolt and oil strainer. C099321E01 (b) Remove the O-ring from the oil strainer. HX O-ring Transmission Oil Strainer C099322E01 11. REMOVE HV MOTOR ASSEMBLY (a) Place the motor on wooden blocks or equivalent. C099323E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–81 12. REMOVE NO. 3 ENGINE MOUNTING BRACKET (a) Remove the 3 bolts and mounting bracket. G022584E01 Motor Revolution Sensor Wiring Harness Connector G032406E01 13. REMOVE MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR (a) Remove the bolt and pull out the HV motor side motor revolution sensor wiring harness connector (gray). NOTICE: Do not pull on the connector any more than necessary. (b) Remove the connector and motor revolution sensor wiring harness connector (gray). 14. REMOVE MOTOR STATOR WIRING HARNESS CONNECTOR (a) Remove the bolt and pull out the motor stator wiring harness connector (black). NOTICE: Do not pull on the sensor connector any more than necessary. (b) Disconnect the connector and the motor stator wiring harness connector (black). Motor Stator Wiring Harness Connector G032407E01 15. REMOVE SHIFT CONTROL ACTUATOR ASSEMBLY (a) Remove the 3 bolts and shift control actuator. Shift Control Actuator C099561E03 16. REMOVE PARKING COVER (a) Remove the 6 bolts and parking cover. C099324E01 HX HX–82 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT 17. REMOVE MANUAL DETENT SPRING SUBASSEMBLY (a) Remove the bolt, manual detent spring cover and manual detent spring. Manual Detent Spring Manual Detent Spring Cover C099325E01 18. REMOVE MOTOR WATER JACKET COVER (a) Remove the 6 bolts and motor water jacket cover. C069307E01 19. REMOVE PARKING SHAFT COVER (a) Remove the 5 bolts and parking shaft cover. C099326E01 20. REMOVE TRANSMISSION OIL PUMP COVER SUBASSEMBLY (a) Remove the oil pump cover plug and O-ring. HX O-Ring C099327E02 (b) Remove the 5 bolts and oil pump cover. C099328E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–83 (c) Remove the O-ring. O-ring G031019E01 Driven Rotor 21. REMOVE OIL PUMP DRIVE SHAFT (a) Remove the oil pump drive rotor and oil pump driven rotor. Drive Rotor C099329E01 (b) Remove the oil pump drive shaft. C099330E01 22. REMOVE DIFFERENTIAL CASE LH TAPERED ROLLER BEARING RACE (a) Using SST, tap out the differential case tapered roller bearing LH outer race and shim. SST 09308-00010 SST G031002E01 23. REMOVE HYBRID TRANSAXLE OIL SEAL LH (a) Place the motor on wooden blocks or equivalent. NOTICE: Make sure that the parking lock rod does not contact the wooden blocks. C099331E01 HX HX–84 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT (b) Using SST, tap out the oil seal. SST 09308-00010 SST G031003E01 24. REMOVE TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG (a) Remove the 2 set plugs and gasket. (b) Using a 10 mm hexagon wrench, remove the screw plugs. Set Plug Screw Plug C099333E01 25. FIX HYBRID VEHICLE GENERATOR ASSEMBLY (a) Place the generator on wooden blocks or equivalent. C069323E01 26. REMOVE POWER CABLE COVER (a) Remove the breather plug. HX C099334E01 (b) Remove the 4 bolts and power cable cover. C099335E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–85 27. REMOVE GENERATOR CABLE (a) Remove the 5 bolts and generator cable. B A A A B C099539E01 C099540E01 28. REMOVE GENERATOR MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR (a) Remove the bolt and pull out the HV generator side generator revolution sensor wiring harness connector. NOTICE: Do not pull on the sensor connector any more than necessary. (b) Disconnect the connector and the HV generator side generator revolution sensor wiring harness connector. 29. REMOVE TRANSAXLE HOUSING TUBE CONNECTOR C069328E01 SST 30. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL (a) Using SST, remove the oil seal. SST 09612-30012 G031004E01 31. REMOVE HYBRID TRANSAXLE OIL SEAL RH (a) Using SST, tap out the oil seal. SST 09308-00010 SST G031005E01 HX HX–86 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT 32. REMOVE DIFFERENTIAL CASE RH TAPERED ROLLER BEARING RACE (a) Using SST, tap out the differential case tapered roller bearing LH outer race. SST 09308-00010 SST G031006E01 33. REMOVE TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG (a) Remove the set plug and gasket. (b) Using a 6 mm socket wrench, remove the screw plug. Screw Plug Set Plug G031007E01 INSPECTION 1. C069413E01 HX Set Plug REASSEMBLY 1. Screw Plug G031008E01 INSPECT HV MOTOR ASSEMBLY (a) Inspect the inside diameter of the rotor bush. (1) Using a caliper gauge, measure the inside diameter of the motor rotor bush. Standard diameter: 20.025 to 20.046 mm (0.7884 to 0.7892 in.) Maximum diameter: 20.096 mm (0.7912 in.) NOTICE: Take the measurement in different locations and use the average of the measurements taken. If the inside diameter exceeds the maximum, replace the motor assembly with a new one. INSTALL TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG (a) Install a new gasket and the set plug. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) (b) Apply liquid sealant 1344 to the first 2 to 3 threads from the end of the screw plug. NOTICE: Clean and degrease the screw and screw hole. (c) Using a 6 mm socket hexagon wrench, install the screw plug. Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–87 2. INSTALL TRANSAXLE HOUSING AND CASE WITH HEAD STRAIGHT SCREW PLUG (a) 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. (b) Apply liquid sealant 1324 to the first 2 to 3 threads from the end of the screw plug. NOTICE: Clean and degrease the screw and screw hole. (c) Using a 10 mm socket hexagon wrench, install the screw plug. Torque: 55 N*m (561 kgf*cm, 41 ft.*lbf) 3. INSTALL HYBRID TRANSAXLE OIL SEAL RH (a) Using SST, tap in a new oil seal. Oil seal depth: 2.7 +-0.5 mm (0.106 +-0.020 in.) (b) Coat the lip of the oil seal with No. 2 MP grease. SST 09350-32014 (09351-32130, 09351-32150), 09950-70010 (09951-07100) 4. INSTALL HYBRID TRANSAXLE TYPE T OIL SEAL LH (a) Place the motor on wooden blocks or equivalent. NOTICE: Make sure that the parking lock rod does not contact the wooden blocks. Set Plug Screw Plug C099333E01 SST G031010E01 C099331E01 HX (b) Using SST, tap in the oil seal. Standard depth: 2.7 +-0.5 mm (0.106 +-0.020 in.) (c) Coat the lip of the oil seal with MP grease. SST 09350-32014 (09351-32130, 09351-32150), 09950-70010 (09951-07100) SST C099542E01 HX–88 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT 5. ADJUST PRELOAD (a) Adjust the differential case preload. (1) Place the motor on wooden blocks or equivalent. NOTICE: • Place the motor horizontally. • Excessive force should not be applied to the cable. C099543E01 (2) Using SST, tap in the differential case tapered roller bearing LH outer race and shim to the motor. SST 09950-60020 (09951-00680), 0995070010 (09951-07100) NOTICE: Replace the shim and outer race with new ones if they are deformed or damaged. SST G031011E01 (3) Using SST, tap in the differential case tapered roller bearing RH outer race to the generator. SST 09950-60020 (09951-00680), 0995070010 (09951-07100) NOTICE: Replace the outer race with a new one if it is deformed or damaged. SST G031012E01 (4) Apply ATF WS to the sliding surfaces of the differential case tapered roller bearing and install the bearing to the motor. HX C069368E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–89 (5) Using an engine sling device and chain block, install the motor to the generator. HINT: • Engine hanger: 12281-67070, S1228-11781 • Bolt: 91642-81045, 91642-81265 • Nut: 90178-10001, 90179-12147 C069026E01 (6) Tighten the 13 bolts in the positions shown in the illustration. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) G030401E01 (7) Using SST, rotate the differential case in both directions to stabilize the bearings. SST 09564-32011 SST G031013E01 SST G031014E01 (8) Using SST, measure the differential preload of the differential case and rotation torque. SST 09564-32011 Standard preload (Starting torque): 0.98 to 1.57 N*m (9.99 to 16.01 kgf*cm, 8.67 to 13.90 in.*lbf) for new bearing 0.49 to 0.78 N*m (5.00 to 7.95 kgf*cm, 4.34 to 6.90 in.*lbf) for reused bearing Standard preload (Turning torque): 0.61 to 1.35 N*m (20 rpm) at 20°C (6.2 to 13.77 kgf*cm, 5.4 to 11.95 in.*lbf) HX HX–90 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HINT: • If the preload is not within the specified range, replace the shim with a new one to adjust the preload. • Remove the motor 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. Standard shim thickness HX Part No. Thickness Mark 90564-45040 1.80 mm (0.0709 in.) 1 90564-45041 1.83 mm (0.0720 in.) 2 90564-45042 1.86 mm (0.0732 in.) 3 90564-45043 1.89 mm (0.0744 in.) 4 90564-45071 1.92 mm (0.0756 in.) 50 90564-45072 1.94 mm (0.0764 in.) 51 90564-45073 1.96 mm (0.0722 in.) 52 90564-45074 1.98 mm (0.0780 in.) 53 90564-45075 2.00 mm (0.0787 in.) 54 90564-45076 2.02 mm (0.0795 in.) 55 90564-45077 2.04 mm (0.0803 in.) 56 90564-45078 2.06 mm (0.0811 in.) 57 90564-45079 2.08 mm (0.0819 in.) 58 90564-45080 2.10 mm (0.0827 in.) 59 90564-45081 2.12 mm (0.0835 in.) 60 90564-45082 2.14 mm (0.0843 in.) 61 90564-45083 2.16 mm (0.0850 in.) 62 90564-45084 2.18 mm (0.0858 in.) 63 90564-45085 2.20 mm (0.0866 in.) 64 90564-45086 2.22 mm (0.0874 in.) 65 90564-45087 2.24 mm (0.0882 in.) 66 90564-45088 2.26 mm (0.0890 in.) 67 90564-45089 2.28 mm (0.0898 in.) 68 90564-45090 2.30 mm (0.0906 in.) 69 90564-45091 2.32 mm (0.0913 in.) 70 90564-45060 2.34 mm (0.0921 in.) 19 90564-45061 2.37 mm (0.0933 in.) 20 90564-45011 2.40 mm (0.0945 in.) No indication 90564-45062 2.43 mm (0.0957 in.) 22 90564-45063 2.46 mm (0.0969 in.) 23 (9) Using an engine sling device and chain block, remove the 13 bolts and generator. HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–91 6. INSTALL DIFFERENTIAL DRIVE PINION (a) Install the differential drive pinion. NOTICE: • Insert the differential drive pinion vertically. • Ensure that the differential drive pinion is fully inserted. 7. SELECT SHIM (a) Select the input shaft shim. (1) Install the No. 1 thrust bearing race. (2) Apply ATF WS to the sliding surfaces of the thrust needle roller bearing and install the flange bearing. (3) Install the thrust bearing race. G032107E01 Thrust Bearing Race Thrust Needle Roller Bearing G031919E01 (4) Install the drive sprocket. Drive Sprocket G031920E01 (5) Install the input shaft. HX Input Shaft G031921E02 (6) Install the No. 1 thrust bearing race. (7) Apply ATF WS to the sliding surfaces of the thrust needle roller bearing and install the flange bearing. (8) Install the thrust bearing race. Thrust Bearing Race Thrust Needle Roller Bearing G031922E01 HX–92 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT (9) Install the planetary ring gear. Planetary Ring Gear G031917E01 (10) Install the planetary ring gear flange. Planetary Ring Gear Flange G031918E01 HX HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT (11) Using a straightedge and vernier caliper, measure dimension A as shown in the illustration. Standard value: Dimension A = Measured value - width of straightedge used NOTICE: • 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 straightedge level. One person should hold the straightedge, and the other person measure dimension A. (12) Using a straightedge and vernier caliper, measure dimension B as shown in the illustration. Standard value: Dimension B = Measured value - thickness of straightedge used NOTICE: Dimension B is greater than dimension A. (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.) NOTICE: Subtract 0.1 mm (0.004 in.) to 0.4 mm (0.016 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 (0.004 in.) to 0.4 mm (0.016 in.) with the input shaft is required. Standard shim thickness A B C099546E01 HX–93 Part No. Thickness Mark 90564-36021 1.00 mm (0.0394 in.) 1 90564-36022 1.20 mm (0.0472 in.) 2 90564-36023 1.40 mm (0.0551 in.) 3 90564-36024 1.60 mm (0.0630 in.) 4 90564-36025 1.80 mm (0.0709 in.) 5 90564-36026 2.00 mm (0.0787 in.) 6 90564-36027 2.20 mm (0.0866 in.) 7 90564-36028 2.40 mm (0.0945 in.) 8 90564-36029 2.60 mm (0.1024 in.) 9 90564-36030 2.80 mm (0.1102 in.) 10 90564-36031 3.00 mm (0.1181 in.) 11 90564-36032 3.20 mm (0.1260 in.) 12 HX HX–94 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT (b) Select a counter drive gear shim. (1) Install the counter drive gear. NOTICE: • Insert the counter drive gear vertically. • Ensure that the counter drive gear is fully inserted. G031916E01 (2) Using a straightedge and vernier caliper, measure dimension A as shown in the illustration. Standard value: Dimension A = Measured value - width of straightedge used NOTICE: • 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 straightedge level. One person should hold the straightedge, and the other person measure dimension A. (3) Using a straightedge and vernier caliper, measure dimension B as shown in the illustration. Standard value: Dimension B = Measured value - thickness of straightedge used NOTICE: Dimension B is greater than dimension A. (4) Select a shim. Standard value: Selected shim = (Dimension B Dimension A) - 0 mm (0 in.) to 0.1 mm (0.004 in.) NOTICE: Subtract 0 mm (0 in.) to 0.1 mm (0.004 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 (0.004 in.) with the counter drive gear is required. Standard shim thickness A HX B C099547E01 Part No. Thickness Mark 90564-35132 2.20 mm (0.0866 in.) A 90564-35133 2.25 mm (0.0886 in.) B 90564-35134 2.30 mm (0.0906 in.) C 90564-35135 2.35 mm (0.0925 in.) D HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT Part No. Thickness Mark 90564-35136 2.40 mm (0.0945 in.) E 90564-35137 2.45 mm (0.0965 in.) F 90564-35138 2.50 mm (0.0984 in.) G 90564-35139 2.55 mm (0.1003 in.) H 90564-35140 2.60 mm (0.1024 in.) J 90564-35141 2.65 mm (0.1043 in.) K 90564-35142 2.70 mm (0.1063 in.) L 90564-35143 2.75 mm (0.1083 in.) M 90564-35144 2.80 mm (0.1102 in.) N 8. Shim HX–95 INSTALL INPUT SHAFT ASSEMBLY (a) Install the shim selected. C099548E01 (b) Install the planetary ring gear flange. (c) Install the thrust bearing race. (d) Install the thrust needle roller bearing. (1) Apply ATF WS to the sliding surfaces of the thrust needle roller bearing and install the flange. (e) Install the thrust bearing race. Thrust Bearing Race Thrust Needle Roller Bearing C069380E02 (f) Planetary Ring Gear Install the planetary ring gear. C099549E01 (g) Install the input shaft. Input Shaft C099550E02 HX HX–96 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT 9. INSTALL SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR (a) Install the counter drive gear shim selected. C099551E01 (b) Install the counter drive gear and chain. NOTICE: • Insert the counter drive gear vertically. • Ensure that the counter drive gear is fully inserted. Chain Counter Drive Gear C099552E01 10. INSTALL TRANSMISSION DRIVE SPROCKET SUBASSEMBLY (a) Apply ATF WS auto fluid to the drive sprocket needle roller bearing and put the drive sprocket on the chain. (b) Align the recesses of the planetary ring gear and the drive sprocket and install the drive sprocket with chain. C069385E01 HX 11. INSTALL NO. 2 THRUST BEARING RACE (a) Install the thrust bearing race. (b) Install the No. 1 drive sprocket thrust needle roller bearing. (1) Apply ATF WS to the sliding surfaces of the thrust needle roller bearing and install the bearing. (c) Install the No. 2 thrust bearing race. Thrust Bearing Race Thrust Needle Roller Bearing C069386E01 12. INSTALL TRANSMISSION OIL STRAINER (a) Apply ATF WS to a new O-ring and install the fluid strainer. O-Ring Transmission Oil Strainer C099322E02 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT HX–97 (b) Install the oil strainer with the bolt. Torque: 7.9 N*m (81 kgf*cm, 70 in.*lbf) C099321E01 FIPG G031015E01 13. INSTALL HYBRID VEHICLE GENERATOR ASSEMBLY (a) Apply seal packing in a continuous line of beads (diameter 1.5 mm 0.059 in.) to the motor side. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: • Clean and degrease the installation surfaces. • Install within 10 minutes of applying seal packing. (b) Using an engine sling device and chain block, install the parking lock rod to the generator so that it is inserted into the cam guide sleeve. NOTICE: Rotate the input shaft in both directions so that the gears interlock if the generator cannot be easily installed. C069392E01 HX C069022E01 C099316E01 (c) Apply adhesive to the first 2 to 3 threads of the bolt end. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent NOTICE: Clean and degrease the bolt and bolt holes. (d) Install the 21 bolts as shown in the illustration. Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) HINT: • 13 bolts on the generator side HX–98 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT • 8 bolts on the motor side SST G031016E01 14. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY TYPE T OIL SEAL (a) Coat the lip of a new oil seal with MP grease. NOTICE: Ensure that no foreign objects adhere to the oil seal lip. (b) Using SST, tap in oil seal. Standard depth: 1 to 1.5 mm (0.039 to 0.059 in.) NOTICE: Ensure that the oil seal is fitted straight. 15. FIX HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Set the hybrid transaxle as shown in the illustration. C099553E01 FIPG C099554E01 HX 16. INSTALL PARKING COVER (a) Apply seal packing in a continuous line of beads (diameter 1.5 mm, 0.06 in.) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: • Clean and degrease the installation surfaces. • Install within 10 minutes of applying seal packing. (b) Install the parking shaft cover with the 5 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) C099326E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT FIPG G032249E01 HX–99 17. INSTALL MOTOR WATER JACKET COVER (a) Apply seal packing black in a continuous line of beads (diameter 1.5 mm, 0.06 in.) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: • Clean and degrease the installation surfaces. • Install within 10 minutes of applying seal packing. (b) Apply adhesive to the first 2 to 3 threads of each of the 6 bolts. Install the motor water jacket cover with the 6 bolts. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) NOTICE: Clean and degrease the bolt and bolt holes. C069307E01 C069328E01 18. INSTALL TRANSAXLE HOUSING TUBE CONNECTOR (a) Apply adhesive to the first 2 to 3 threads of the bolt and install. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf) NOTICE: Clean and degrease the bolt and bolt holes. (b) Install the drain plug using a new gasket. Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf) 19. INSTALL MANUAL DETENT SPRING SUBASSEMBLY (a) Install the manual detent spring and manual detent spring cover with the bolt. Torque: 9.8 N*m (100 kgf*cm, 86 in.*lbf) Manual Detent Spring Manual Detent Spring Cover C099325E01 HX HX–100 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT FIPG G031018E01 20. REMOVE PARKING COVER (a) Apply seal packing in a continuous line of beads (diameter 1.5 mm, 0.06 in) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: • Clean and degrease the installation surfaces. • Install within 10 minutes of applying seal packing. (b) Install the parking cover with the 6 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) C099324E01 21. INSTALL SHIFT CONTROL ACTUATOR ASSEMBLY (a) Apply a small amount of genuine ATF WS to the Oring. G030526E01 (b) Install the shift control actuator with the 3 bolts. Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf) (c) Install the transmission case cover with the 3 bolts. HX C099561E02 22. INSTALL OIL PUMP DRIVE SHAFT (a) Apply ATF WS to the fluid pump drive shaft and install it. C099330E01 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT Driven Rotor HX–101 23. INSTALL OIL PUMP DRIVEN ROTOR (a) Apply ATF WS to the fluid pump driven rotor and install it. C099329E02 24. INSTALL TRANSAXLE OIL PUMP DRIVE ROTOR (a) Apply ATF WS to the transaxle fluid pump drive rotor and install it. Drive Rotor C099329E03 25. INSTALL TRANSMISSION OIL PUMP COVER SUBASSEMBLY (a) Install a new O-ring. NOTICE: Ensure that the O-ring is not twisted. O-Ring G031019E02 (b) Apply adhesive to the first 2 to 3 threads of the bolt end. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent NOTICE: Clean and degrease the bolts and bolt holes. (c) Install the oil pump cover with the 5 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) C099328E01 (d) Install a new O-ring and fluid pump cover plug. O-Ring C099327E02 HX HX–102 HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT 26. INSTALL MOTOR STATOR WIRING HARNESS CONNECTOR (a) Apply ATF WS to the O-ring and install the motor stator wiring harness connectors (black) with the bolt. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) Motor Stator Wiring Harness Connector G032407E01 27. INSTALL MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR (a) Apply ATF WS to the O-ring and install the HV motor side motor revolution sensor wiring harness connectors (gray) with the bolt. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) Motor Revolution Sensor Wiring Harness Connector G032406E01 28. INSTALL GENERATOR MOTOR REVOLUTION SENSOR WIRING HARNESS CONNECTOR (a) Apply ATF WS to the O-ring and install the HV generator side generator motor revolution sensor wiring harness connector with the bolt. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) C099540E01 HX B A A A B C099539E01 29. INSTALL GENERATOR CABLE (a) Align the generator cables as shown in the illustration and connect them. NOTICE: • Aligning the letters U, V and W, and connect the cable. • Apply a small amount of ATF WS to the Oring. (b) Apply adhesive to the first 2 or 3 threads of bolts B and install the generator cable with the bolts. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) (bolt B) Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent NOTICE: Clean and degrease the bolts and bolt holes. (c) Install the generator cable with the 3 bolts (A). Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) (bolt A) HYBRID TRANSMISSION / TRANSAXLE – HYBRID VEHICLE TRANSAXLE UNIT FIPG C098385E01 HX–103 30. INSTALL POWER CABLE COVER (a) Apply seal packing in a continuous line of beads (diameter 1.5 mm 0.06 in.) as shown in the illustration. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: • Clean and degrease the installation surfaces. • Install within 10 minutes of applying seal packing. (b) Apply adhesive to the first 2 or 3 threads of the 4 bolts and install the power cable cover. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent Torque: 4.8 N*m (49 kgf*cm, 42 in.*lbf) NOTICE: Clean and degrease the bolts and bolt holes. C099335E01 (c) Install the breather plug. Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf) C099334E01 31. INSTALL NO. 3 ENGINE MOUNTING BRACKET (a) Apply adhesive to the first 2 or 3 threads of the 3 bolts and install the engine mounting bracket. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) NOTICE: Clean and degrease the bolts and bolt holes. G022584E01 32. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY HX HX–104 HYBRID TRANSMISSION / TRANSAXLE – INPUT SHAFT INPUT SHAFT HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS NO. 1 INPUT SHAFT THRUST BEARING RACE INPUT SHAFT THRUST NEEDLE ROLLER NO. 1 BEARING INPUT SHAFT ASSEMBLY HX NO. 2 INPUT SHAFT THRUST BEARING RACE PLANETARY SUN GEAR SUB-ASSEMBLY Apply ATF WS C130900E01 HYBRID TRANSMISSION / TRANSAXLE – INPUT SHAFT HX–105 DISASSEMBLY 1. REMOVE PLANETARY SUN GEAR SUB-ASSEMBLY (a) Remove the planetary sun gear from the input shaft. 2. REMOVE INPUT SHAFT THRUST BEARING RACE (a) Float the input shaft thrust bearing race using a thin flat-head screwdriver if it is attached to the planetary sun gear. C069341E01 C069342E01 (b) Remove the 2 input shaft thrust bearing races and input shaft thrust needle roller bearing. Input Shaft Thrust Needle Roller Bearing C069343E01 HX HX–106 HYBRID TRANSMISSION / TRANSAXLE – INPUT SHAFT INSPECTION 1. INSPECT PLANETARY SUN GEAR SUB-ASSEMBLY (a) Ensure that there is no damage or color change in the bush. (b) Using a caliper gauge, inspect the internal diameter of the planetary gear. C069344E01 Maximum diameter: 25.596 mm (1.0077 in.) NOTICE: Measure the diameter in a number of locations and use the average of the measurements taken. HINT: Replace the planetary sun gear with a new one if the measurement exceeds the maximum diameter. C069345E01 2. HX INSPECT INPUT SHAFT THRUST NEEDLE ROLLER NO. 1 BEARING (a) Ensure that there is no abnormal wear or discoloration in the bearing. HINT: Replace the input shaft thrust needle roller bearing with a new one if there is abnormal wear or discoloration. C069286E01 REASSEMBLY 1. Input Shaft Thrust Needle Roller Bearing C069343E03 INSTALL INPUT SHAFT THRUST BEARING RACE (a) Apply ATF WS to the sliding surfaces of the bearing and install the 2 input shaft thrust bearing races and input shaft thrust needle roller bearing. HYBRID TRANSMISSION / TRANSAXLE – INPUT SHAFT 2. HX–107 INSTALL PLANETARY SUN GEAR SUB-ASSEMBLY (a) Apply ATF WS to the bush and install the planetary sun gear to the input shaft. C069341E02 HX HYBRID TRANSMISSION / TRANSAXLE – SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR HX–107 SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS COUNTER DRIVE GEAR RADIAL BALL BEARING COUNTER DRIVE GEAR HX COUNTER DRIVE GEAR RADIAL BALL BEARING C130910E01 HX–108 HYBRID TRANSMISSION / TRANSAXLE – SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR DISASSEMBLY SST 1. REMOVE COUNTER DRIVE GEAR RADIAL BALL BEARING (a) Using SST and a press, press out the bearing from the counter drive gear. SST 09950-00020, 09950-60010 (09951-00330), 09950-70010 (09951-07100) C069348E01 SST C069349E02 HX (b) Using SST and a press, press out the bearing from the counter drive gear. SST 09950-00020, 09950-60010 (09951-00330), 09950-70010 (09951-07100) HYBRID TRANSMISSION / TRANSAXLE – SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR HX–109 INSPECTION 1. INSPECT COUNTER DRIVE GEAR RADIAL BALL BEARING (a) Check the bearing for abnormal wear or discoloration. HINT: Replace the bearing with a new one if abnormal wear or discoloration is found. HX HX–110 HYBRID TRANSMISSION / TRANSAXLE – SPROCKET DRIVEN GEAR AND COUNTER DRIVE GEAR REASSEMBLY 1. SST INSTALL COUNTER DRIVE GEAR RADIAL BALL BEARING (a) Apply ATF WS to the 2 bearings. (b) Using SST and a press, press in the bearing to the counter drive gear. SST 09950-60010 (09951-00330, 09951-00460), 09950-70010 (09951-07100) C069350E01 SST SST C069351E01 HX (c) Using SST and a press, press in the bearing to the counter drive gear. SST 09950-60010 (09951-00330, 09951-00460), 09950-70010 (09951-07100) HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL DRIVE PINION HX–109 DIFFERENTIAL DRIVE PINION HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS COUNTER DRIVE GEAR RADIAL BALL BEARING 280 (2,860, 207) HX DIFFERENTIAL DRIVE PINION COUNTER DRIVE GEAR RADIAL BALL BEARING N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply ATF WS C130901E01 HX–110 HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL DRIVE PINION DISASSEMBLY 1. REMOVE COUNTER DRIVE GEAR RADIAL BALL BEARING (a) Loosen the staked part of the nut. C099559E01 (b) Set the differential drive pinion in a vise and remove the nut using a deep socket wrench. HINT: Set the drive pinion in a vise as shown in the illustration. G030576E01 (c) Using SST and a press, press out the bearing from the differential driver pinion. SST 09527-10011, 09950-00020, 09950-60010 (09951-00360), 09950-70010 (09951-07100) SST HX G030577E01 SST G030578E01 (d) Using SST and a press, press out the bearing from the differential drive pinion. SST 09527-10011, 09950-00020, 09950-60010 (09951-00360), 09950-70010 (09951-07100) HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL DRIVE PINION HX–111 INSPECTION 1. INSPECT COUNTER DRIVE GEAR RADIAL BALL BEARING (a) Check the bearing for abnormal wear or discoloration. HINT: Replace the bearing with a new one if abnormal wear or discoloration is found. REASSEMBLY 1. SST INSTALL COUNTER DRIVE GEAR RADIAL BALL BEARING (a) Using SST and a press, press in the bearing to the differential drive pinion. SST 09608-06041 G030579E01 SST (b) Using SST and a press, press in the bearing to the differential drive pinion. SST 09608-06041, 09950-60010 (09951-00370) G030580E01 (c) Set the differential drive pinion in a vise and tighten a new nut using a deep socket wrench. Torque: 280 N*m (2,860 kgf*cm, 207 ft.*lbf) HINT: Set the vise as shown in the illustration. G030576E01 (d) Stake the nut. C099559E01 HX HX–112 HYBRID TRANSMISSION / TRANSAXLE – TRANSMISSION DRIVE SPROCKET TRANSMISSION DRIVE SPROCKET HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS SNAP RING SPACER HX NO. 2 DRIVE SPROCKET NEEDLE ROLLER BEARING TRANSMISSION DRIVE SPROCKET SUB-ASSEMBLY Apply ATF WS C130902E01 HYBRID TRANSMISSION / TRANSAXLE – TRANSMISSION DRIVE SPROCKET HX–113 DISASSEMBLY 1. REMOVE TRANSMISSION DRIVE SPROCKET SUBASSEMBLY (a) Using a thin screwdriver, pry out the snap ring from the transmission drive sprocket. C069346E01 (b) Remove the spacer and the needle roller bearing from the transmission drive sprocket. C069347E01 INSPECTION 1. INSPECT NO. 2 DRIVE SPROCKET NEEDLE ROLLER BEARING (a) Check the bearing for abnormal wear or discoloration. HINT: Replace the needle roller bearing with a new one if abnormal wear or discoloration is found. C069285E01 REASSEMBLY 1. INSTALL TRANSMISSION DRIVE SPROCKET SUBASSEMBLY (a) Apply ATF WS to the sliding surfaces of the bearing and install the needle roller bearing to the transmission drive sprocket. (b) Install the spacer to the transmission drive sprocket. C069347E01 (c) Using a thin screwdriver, install the snap ring to the transmission drive sprocket. C069346E01 HX HX–114 HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL CASE DIFFERENTIAL CASE HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS DIFFERENTIAL CASE RH TAPERED ROLLER BEARING DIFFERENTIAL CASE DIFFERENTIAL CASE LH TAPERED ROLLER BEARING PINION THRUST WASHER SIDE GEAR SIDE GEAR THRUST WASHER PINION GEAR HX SIDE GEAR PINION SHAFT PINION GEAR PINION THRUST WASHER SIDE GEAR THRUST WASHER STRAIGHT PIN Apply ATF WS C130903E01 HX–115 HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL CASE DISASSEMBLY 1. REMOVE DIFFERENTIAL CASE LH TAPERED ROLLER BEARING (a) Set the differential case in a vise. (b) Using SST, remove the bearing RH from the differential case. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09958-04010) NOTICE: Apply oil or equivalent to the ends and screw portions of SST. 2. REMOVE DIFFERENTIAL CASE RH TAPERED ROLLER BEARING (a) Set the differential case in a vise. (b) Using SST, remove the bearing LH from the differential case. SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09958-04010) 3. REMOVE DIFFERENTIAL CASE (a) Set the differential case in a vise. (b) Tap out the straight pin from the differential case with a 5 mm pin punch. SST C069352E01 SST C069353E01 C069354E01 (c) Remove the following parts from the differential case. 3 2 5 4 5 4 1 2 3 C069283E01 Number Part Number of Parts 1 Pinion shaft 1 2 Pinion 2 3 Pinion thrust washer 2 4 Side gear 2 5 Side gear thrust washer 2 HX HX–116 HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL CASE INSPECTION 1. INSPECT DIFFERENTIAL CASE TAPERED ROLLER BEARING (a) Check the bearing for abnormal wear or discoloration. HINT: Replace the bearing with a new one if abnormal wear or discoloration is found. REASSEMBLY 1. C069355E01 C069418E01 HX INSTALL DIFFERENTIAL CASE (a) Apply ATF WS to the side gear thrust washer and install it to the side gear. (b) Apply ATF WS to the side gear thrust washer and install it to the pinion. (c) Install the side gear and pinion to the differential case. (d) Install the pinion shaft to the differential case so that the straight pin holes of the pinion shaft and differential case are aligned. (e) Set the pinion side and inspect the side gear backlash. Standard backlash: 0.05 to 0.20 mm (0.0020 to 0.0079 in.) HINT: • Replace the side gear thrust washers with the same size for both the right and left side gears if the value is outside the specified range. • Ensure that rotation is smooth if side gear backlash is within the specified range. If the backlash exceeds the specified range, replace the side gear thrust washer with thinner one. If the backlash is less then the specified range, replace the side gear thrust washer with thicker one. Standard side gear thrust washer thickness Part No. Washer thickness 41361-22140 0.95 mm (0.0374 in.) 41361-22020 1.00 mm (0.0394 in.) 41361-22150 1.05 mm (0.0414 in.) 41361-22030 1.10 mm (0.0433 in.) 41361-22160 1.15 mm (0.0453 in.) 41361-22040 1.20 mm (0.0472 in.) (f) C069356E01 Using a 5 mm pin punch, tap in the straight pin to the differential case. HYBRID TRANSMISSION / TRANSAXLE – DIFFERENTIAL CASE HX–117 (g) Using a chisel, caulk the external circumference of the differential case straight pin hole. C069019E01 2. INSTALL DIFFERENTIAL CASE RH TAPERED ROLLER BEARING (a) Using SST and a press, press in the bearing RH to the differential case. SST 09710-22021 (09710-01031), 09950-70010 (09951-07100) HINT: There are 24 bearing rollers in bearing RH. 3. INSTALL DIFFERENTIAL CASE LH TAPERED ROLLER BEARING (a) Using SST and a press, press in the bearing LH to the differential case. SST 09710-22021 (09710-01031), 09950-70010 (09951-07100) HINT: There are 22 bearing rollers in bearing LH. SST C069357E01 SST C069358E01 HX HX–118 HYBRID TRANSMISSION / TRANSAXLE – GENERATOR CABLE GENERATOR CABLE REMOVAL CAUTION: • When working on the high voltage systems, always wear insulated gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. HX G021868E01 1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation. 2. REMOVE SERVICE PLUG GRIP (a) Remove the service plug grip (see page HB-153). 3. REMOVE ENGINE UNDER COVER LH 4. REMOVE ENGINE UNDER COVER RH 5. DRAIN COOLANT (a) Drain coolant (see page HX-58). 6. REMOVE FRONT COWL TOP PANEL OUTER SUBASSEMBLY (a) Remove the cowl top front panel (see page FU-12). 7. REMOVE INVERTER WITH CONVERTER ASSEMBLY (a) Remove the inverter with converter (see page HV530). 8. REMOVE GENERATOR CABLE (a) Check that there is no voltage. CAUTION: Ensure that insulated gloves are worn when carrying out this procedure. (1) Remove the 4 bolts and power cable cover. HYBRID TRANSMISSION / TRANSAXLE – GENERATOR CABLE HX–119 (2) Remove the 2 bolts from the generator cable. C098381E01 (3) Inspect the voltage between each of the 3 phase AC terminals (U to V, V to W, U to W) and body ground using the Toyota electrical tester. Standard value: 0V HINT: Use the Toyota Electrical Tester on measured ranges of DC 400 volts or more. C098382E01 (b) Remove the 3 bolts and generator cable. C098383E01 INSTALLATION 1. INSTALL GENERATOR CABLE (a) Apply a small amount of ATF WS to the generator cable's O-ring. G030264E01 (b) Connect the generator cable as shown in the illustration. NOTICE: • Align the letters U, V and W, and connect the cable. • Ensure that no foreign objects are attached to the O-ring when connecting the cables. C098382E01 HX HX–120 HYBRID TRANSMISSION / TRANSAXLE – GENERATOR CABLE (c) Install the generator cable (terminals) with the 3 bolts. Torque: 8.5 N*m (87 kgf*cm, 71 in.*lbf) C098383E01 (d) Install the generator cable with the 2 bolts. Torque: 5.8 N*m (59 kgf*cm, 51 in.*lbf) C098381E01 (e) Apply seal packing in a continuous line of beads (diameter 1.5 mm (0.059 in.) to the power cable cover. Seal packing: Toyota Genuine Seal Packing 1281, Three Bond 1281 or Equivalent NOTICE: • Clean and degrease the installation surfaces. • Install within 10 minutes of applying seal packing. • Ensure that no foreign objects are inserted when the power cable cover is attached. FIPG C098385E01 HX (f) G021868E01 Install the power cable cover with the 4 bolts. Torque: 4.8 N*m (49 kgf*cm, 42 in.*lbf) 2. INSTALL INVERTER WITH CONVERTER ASSEMBLY (a) Install the inverter with converter (see page HV535). 3. INSTALL FRONT COWL TOP PANEL OUTER SUBASSEMBLY (a) Install the cowl top front panel (see page FU-19). 4. INSTALL ENGINE UNDER COVER RH 5. INSTALL ENGINE UNDER COVER LH 6. INSTALL SERVICE PLUG GRIP (a) Install the service plug grip (see page HB-154). 7. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 8. ADD COOLANT (a) Add coolant (see page HX-58). HYBRID TRANSMISSION / TRANSAXLE – GENERATOR CABLE 9. HX–121 CHECK FOR ENGINE COOLANT LEAKS (a) Check for engine coolant leaks (see page CO-9). 10. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. HX HX–122 HYBRID TRANSMISSION / TRANSAXLE – SHIFT LEVER SHIFT LEVER HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY SHIFT LEVER ASSEMBLY 12 (122, 9) HX LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque C130905E01 HYBRID TRANSMISSION / TRANSAXLE – SHIFT LEVER HX–123 INDICATOR LIGHT WIRE SUB-ASSEMBLY SHIFT LOCK CONTROL UNIT CAP BULB HX COVER C130906E01 HX–124 HYBRID TRANSMISSION / TRANSAXLE – SHIFT LEVER REMOVAL 1. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-5) 2. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-6) 3. REMOVE UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-6) 4. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-6) 5. REMOVE SHIFT LEVER ASSEMBLY (a) Remove the 3 bolts. (b) Disconnect the 2 connectors and remove the shift lever. G021871E01 DISASSEMBLY 1. REMOVE INDICATOR LIGHT WIRE SUB-ASSEMBLY (a) Remove the position indicator light wire from the position indicator housing. HX G022473E01 (b) Remove the cover. (c) Disconnect the connector from the 3 clamps and remove the position indicator light wire. G032250E01 HYBRID TRANSMISSION / TRANSAXLE – SHIFT LEVER HX–125 (d) Remove the bulb and cap from the position indicator light wire. C097950E01 REASSEMBLY 1. INSTALL INDICATOR LIGHT WIRE SUB-ASSEMBLY (a) Install the bulb and cap to the position indicator light wire. C097950E01 (b) Connect the connector to the 3 clamps. (c) Install the cover. HX G032250E01 (d) Install the position indicator light wire to the position indicator housing. NOTICE: Securely attach the wire by twisting to the right. G022473E01 HX–126 HYBRID TRANSMISSION / TRANSAXLE – SHIFT LEVER INSTALLATION G021871E01 HX 1. INSTALL SHIFT LEVER ASSEMBLY (a) Connect the 2 connectors to the shift lever. (b) Install the shift lever with the 3 bolts. Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 2. INSPECT SHIFT LEVER ASSEMBLY (a) Inspect the shift lever (see page HX-2). 3. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) 4. INSTALL UPPER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-13) 5. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See page IP-13) 6. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See page IP-13) HYBRID TRANSMISSION / TRANSAXLE – OIL PUMP DRIVE SHAFT HX–127 OIL PUMP DRIVE SHAFT HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS OIL PUMP DRIVE SHAFT x5 5.5 (56, 49 in.*lbf) HX OIL PUMP DRIVEN ROTOR TRANSAXLE OIL PUMP DRIVE ROTOR O-RING TRANSMISSION OIL PUMP COVER SUB-ASSEMBLY ENGINE UNDER COVER LH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Apply ATF WS C130907E01 HX–128 HYBRID TRANSMISSION / TRANSAXLE – OIL PUMP DRIVE SHAFT REMOVAL 1. REMOVE FRONT WHEEL LH 2. REMOVE ENGINE UNDER COVER LH 3. DRAIN TRANSAXLE OIL (a) Drain transaxle oil (see page HX-1). 4. REMOVE TRANSMISSION OIL PUMP COVER SUBASSEMBLY (a) Remove the 5 bolts and oil pump cover. C069315E01 (b) Remove the O-ring. O-Ring G031019E02 5. REMOVE TRANSAXLE OIL PUMP DRIVE ROTOR (a) Remove the transaxle oil pump drive rotor from the hybrid vehicle transaxle. 6. REMOVE OIL PUMP DRIVEN ROTOR (a) Remove the oil pump driven rotor from the hybrid vehicle transaxle. HX Drive Rotor C099329E03 Driven Rotor C099329E02 HYBRID TRANSMISSION / TRANSAXLE – OIL PUMP DRIVE SHAFT 7. HX–129 REMOVE OIL PUMP DRIVE SHAFT (a) Remove the oil pump drive shaft from the hybrid vehicle transaxle. C069318E01 INSTALLATION 1. INSTALL OIL PUMP DRIVE SHAFT (a) Apply ATF WS to the oil pump drive shaft and install it to the hybrid vehicle transaxle. HINT: Use genuine ATF WS. 2. INSTALL OIL PUMP DRIVEN ROTOR (a) Apply ATF WS to the oil pump driven rotor and install it to the hybrid vehicle transaxle. HINT: Use genuine ATF WS. 3. INSTALL TRANSAXLE OIL PUMP DRIVE ROTOR (a) Apply ATF WS to the oil pump drive rotor and install it to the hybrid vehicle transaxle. HINT: Use genuine ATF WS. C069318E01 Driven Rotor C099329E02 Drive Rotor C099329E03 4. O-ring G031019E01 INSTALL TRANSMISSION OIL PUMP COVER SUBASSEMBLY (a) Install a new O-ring to the hybrid transaxle. NOTICE: Do not twist the O-ring when installing it. HX HX–130 HYBRID TRANSMISSION / TRANSAXLE – OIL PUMP DRIVE SHAFT (b) Apply adhesive to the first 2 or 3 threads of the bolt end. Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or Equivalent NOTICE: Clean and degrease the bolts and bolt holes. (c) Install the oil pump cover with the 5 bolts. Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) C069315E01 HX 5. INSTALL FRONT WHEEL 6. ADD TRANSAXLE OIL Fluid type: Toyota genuine ATF WS Standard capacity: 3.8 liters (4.0 US qts, 3.3 Imp. qts) 7. INSPECT TRANSAXLE OIL (a) Inspect transaxle oil (see page HX-1). 8. INSTALL ENGINE UNDER COVER LH HYBRID TRANSMISSION / TRANSAXLE – HYBRID TRANSAXLE OIL SEAL HX–131 HYBRID TRANSAXLE OIL SEAL HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS FRONT DRIVE SHAFT HOLE SNAP RING FRONT DRIVE SHAFT ASSEMBLY RH HYBRID VEHICLE TRANSAXLE OIL SEAL FRONT DRIVE SHAFT ASSEMBLY LH FRONT SPEED SENSOR LH 8.0 (82, 71 in.*lbf) CLIP 29 (296, 21) 49 (500, 36) HX TIE ROD END SUB-ASSEMBLY LH 216 (2,203, 159) 89 (908, 66) FRONT AXLE HUB NUT LH ENGINE UNDER COVER RH N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part ENGINE UNDER COVER LH C130904E01 HX–132 HYBRID TRANSMISSION / TRANSAXLE – HYBRID TRANSAXLE OIL SEAL REPLACEMENT 1. REMOVE FRONT WHEEL 2. REMOVE ENGINE UNDER COVER LH 3. REMOVE ENGINE UNDER COVER RH 4. DRAIN TRANSAXLE OIL (a) Drain transaxle oil (see page HX-1). 5. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (a) Remove the drive shaft (see page DS-7). 6. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (a) Remove the drive shaft (see page DS-7). 7. REMOVE HYBRID TRANSAXLE OIL SEAL (a) Using SST, tap out the oil seal. SST 09308-00010 8. INSTALL HYBRID TRANSAXLE OIL SEAL (a) Apply a small amount of No. 2 MP grease to the lip of a new oil seal. (b) Using SST, tap in the oil seal to the standard depth. Standard depth: 2.7 +-0.5 mm (0.106 +-0.020 in.) SST 09950-70010 (09951-07200), 09350-32014 (09351-32130, 09351-32150) 9. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (a) Install the front drive shaft (see page DS-15). SST G021806E01 SST HX G021807E01 10. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (a) Install the front drive shaft (see page DS-15). 11. INSTALL FRONT WHEEL 12. ADD TRANSAXLE OIL Fluid type: Toyota genuine ATF WS Capacity: 3.8 liters (4.0 US qts, 3.3 Imp. qts) 13. INSPECT TRANSAXLE OIL (a) Inspect the transaxle oil level (see page HX-1). 14. INSTALL ENGINE UNDER COVER RH 15. INSTALL ENGINE UNDER COVER LH 16. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (a) Inspect and adjust the front wheel alignment (see page SP-2). HYBRID TRANSMISSION / TRANSAXLE – HYBRID TRANSAXLE OIL SEAL HX–133 17. PERFORM CALIBRATION (a) Perform calibration (see page PS-13). HX HX–134 HYBRID TRANSMISSION / TRANSAXLE – INPUT SHAFT OIL SEAL INPUT SHAFT OIL SEAL HYBRID SYSTEM TRANSMISSION / TRANSAXLE COMPONENTS HYBRID VEHICLE TRANSAXLE ASSEMBLY HX INPUT SHAFT OIL SEAL Non-reusable part C130908E01 HYBRID TRANSMISSION / TRANSAXLE – INPUT SHAFT OIL SEAL HX–135 REPLACEMENT CAUTION: • When working on the high voltage systems, always wear insulated gloves. • Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle. • After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes. NOTICE: After removing the service plug grip, do not operate the power switch as it may damage the hybrid vehicle control ECU. 1. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Remove the hybrid vehicle transaxle (see page HX66). 2. REMOVE INPUT SHAFT OIL SEAL (a) Insert a flat-head screwdriver into the metal portion of the oil seal and pry out the oil seal. NOTICE: Do not damage the input shaft and transaxle housing when inserting the screwdriver or removing the oil seal. 3. INSTALL INPUT SHAFT OIL SEAL (a) Apply a small amount of No. 2 MP grease to the lip of a new oil seal. (b) Using SST, install the oil seal. SST 09388-40010 Standard depth: 1.0 to 1.5 mm (0.039 to 0.059 in.) NOTICE: • Ensure that no foreign objects adhere to the oil seal lip. • Ensure that the oil seal is not at an angle. C069360E01 SST G031020E01 4. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY (a) Install the hybrid vehicle transaxle (see page HX70). HX