HV Battery: Reassembly

Using a dial indicator, measure the inside diameter of the rotor bush.

Fig 1: Measuring Rotor Bush Inside Diameter

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Standard diameter: 

20.025-20.046 mm (0.78838-0.78921 in.) 

Maximum diameter: 

20.096 mm (0.79118 in.) 

If the inside diameter exceeds the limit, replace the MG2 assembly.

1. Apply liquid sealer to the screw plug and install it to the MG1 assembly with a hexagon wrench.
   Fig 3: Installing gasket and drain plug

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Sealant: 

   Part No. 08833-00080, TREE BOND 1344, LOCTITE 

   242 or equivalent 

   Torque: 12.7 N.m (130 kgf.cm, 9 ft.lbf) 

2. Install a new gasket and the drain plug.

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

1. Apply liquid sealer to the 2 screw plugs and install them to the MG2 assembly with a hexagon wrench.
   Fig 5: Installing Filler Plugs

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Sealant: 

   A: Part No. 08833-00070, THREE BOND 1324 or equivalent 

   B: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

   Torque: 24.5 N.m (250 kgf.cm, 18 ft.lbf) 

   CAUTION: Be careful not to bend the parking lock rod.
2. Install 2 new gaskets and the 2 filler plugs.

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

1. Using SST and a hammer, install a new oil seal. SST 09710-20011 (09710-06071), 09950-70010 (09951-07100)
   Fig 6: Installing Differential Oil Seal RH (MG1 Side)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Oil seal depth: 2.7 +/- 0.5 mm (0.106 +/- 0.020 in.) 

2. Coat the lip of the oil seal with MP grease.

1. Using SST and a hammer, install a new oil seal LH. SST 09710-20011 (09710-06071), 09950-70010 (09951-07100)
   Fig 7: Installing Differential Oil Seal LH (MG2 Side)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Oil seal depth: 2.7 +/- 0.5 mm (0.106 +/- 0.020 in.) 

2. Coat the lip of the oil seal with MP grease.

Fig 8: Installing Breather Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 11.3 N.m (111 kgf.cm, 8 ft.lbf) 

1. Place a wood block under the MG2 assembly to stabilize.
   Fig 9: Placing Wood Block Under MG2 Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   CAUTION:

   • Set the MG2 assembly horizontally. 
   • Unreasonable force should not be applied to the high-voltage cable. 
2. MG2 side:

   Using SST and a hammer, install the outer race of differential side bearing LH and shim.

   SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)

   NOTE: If replacing the shim, install a new shim which has the same thickness with the removed.
   Fig 10: Installing Differential Side Bearing LH And Shim Outer Race

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. MG2 side:

   Using SST and a hammer, install the tapered roller bearing outer race LH of the counter driven gear and shim. SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)

   Fig 11: Installing Tapered Roller Bearing Outer Race LH of Counter Driven Gear And Shim

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: If replacing the shim, install a new shim which has the same thickness with the removed.
4. MG1 side:

   Using SST and a hammer, install the side bearing outer race RH of the differential. SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)

   Fig 12: Installing Side Bearing Outer Race RH Of Differential

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. MG1 side:

   Using SST and a hammer, install the tapered roller bearing outer race RH of the counter driven gear. SST 09950-60020 (09951-00680), 09950-70010 (09951-07100)

   Fig 13: Installing Tapered Roller Bearing Outer Race RH Of Counter Driven Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the differential assembly to the MG2 assembly.
   Fig 14: Installing Differential To MG2 Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Apply ATF to the side bearing.
2. Install the engine hanger onto the MG1 side as shown in Fig 15, and lift it up by a chain device.
   Fig 15: Installing Engine Hanger Onto MG1 Side

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Engine hanger part No.: 

   12281-67070, S1228-11781 

   Bolt part No.: 91642-81045 91642-81265 2 pieces 

   Nut part No.: 90178-10001 90179-12147 2 pieces 

3. Install the 13 bolts and MG1 assembly to the MG2 assembly.
   Fig 16: Installing MG1 Assembly To MG2 Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

4. Using SST, rotate the differential case assembly in both directions to make it fit.
   Fig 17: Rotating Differential Case Assembly In Both Directions For Proper Fitting

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09564-32011

5. Using SST and a small torque wrench, measure the differential preload.
   Fig 18: Measuring Differential Preload

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09564-3201 1

   Preload (Starting torque): 

   New bearing 

   0.98 - 1.57 N.m 

   (9.99 - 16.01 kgf.cm, 8.67 - 13.90 in..lbf) 

   Reused bearing 

   0.49 - 0.78 N.m 

   (5.00 - 7.95 kgf.cm, 4.34 - 6.90 in..lbf) 

   Preload (Turning torque): 

   0.78 - 1.37 N.m (60 rpm) 

   (7.95 - 13.97 kgf.cm, 6.90 - 12.13 in..lbf) 

   If the preload is not within the specified range, replace the shim of the differential outer race LH.

   SHIM THICKNESS SPECIFICATIONS
   
   

   Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
   1	1.80 (0.0709)	61	2.14 (0.0843)
   2	1.83 (0.0720)	62	2.16 (0.0850)
   3	1.86 (0.0732)	63	2.18 (0.0858
   4	1.89 (0.0744)	64	2.20 (0.0866)
   50	1.92 (0.0756)	65	2.22 (0.0874)
   51	1.94 (0.0764)	66	2.24 (0.0882)
   52	1.96 (0.0772)	67	2.26 (0.0890)
   53	1.98 (0.0780)	68	2.28 (0.0898)
   54	2.00 (0.0787)	69	2.30 (0.0906)
   55	2.02 (0.0795)	70	2.32 (0.0913)
   56	2.04 (0.0803)	19	2.34 (0.0921)
   57	2.06 (0.0811)	20	2.37 (0.0933)
   58	2.08 (0.0819)	-	2.40 (0.0945)
   59	2.10 (0.0827)	22	2.43 (0.0957)
   60	2.12 (0.0835)	23	2.46 (0.0969)

   NOTE: As a rank of shim thickness is increased (0.020 mm), the preload of approx. 0.23 N.m (2.4 kgf.cm, 2.1 in..lbf) is increased accordingly.

1. Remove the 13 bolts, separate the MG1 assembly and the MG2 assembly.
2. Install the counter driven gear to the MG2 assembly.
   NOTE: Apply ATF to the side bearing.
   Fig 19: Installing Counter Driven Gear To MG2 Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the engine hanger onto the MG1 side as shown in the illustration, and lift it up by a chain device.

   Engine hanger part No.: 

   12281 - 67070, S1228 - 11781 

   Bolt part No.: 

   91642 - 81045 

   91642 - 81265 2 pieces 

   Nut part No.: 

   90178 - 10001 

   90179 - 12147 2 pieces 

   Fig 20: Installing Engine Hanger Onto MG1 Side

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the MG1 assembly to the MG2 assembly with the 13 bolts.
   Fig 21: Installing MG1 Assembly To MG2 Assembly Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

5. Using SST, rotate the differential case assembly in both directions to make it fit.
   Fig 22: Rotating Differential Case Assembly In Both Directions For Proper Fitting

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09564-3201 1

6. Using SST and a small torque wrench, measure the counter driven gear preload.
   Fig 23: Measuring Counter Driven Gear Preload

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09564-3201 1

   Preload (Starting torque): 

   New bearing 

   3.81 - 6.10 N.m 

   (38.85 - 62.20 kgf.cm, 33.72 - 53.99 in..lbf) 

   Reused bearing 

   1.91 - 3.03 N.m 

   (19.48 - 30.90 kgf.cm, 16.91 - 26.82 in..lbf) 

   Preload (Turning torque): 

   3.29 - 6.66 N.m (60 rpm) 

   (33.55 - 67.91 kgf.cm, 29.12 - 58.95 in..lbf) 

   If the preload is not within the specified range, replace the shim of the counter driven gear LH.

1. Install the 2 bearing races and needle roller bearing to the MG1 assembly.
   Fig 24: Installing Bearing Races And Needle Roller Bearing To MG1 Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the drive sprocket assembly to the MG1 assembly.
   Fig 25: Installing Drive Sprocket Assembly To MG1 Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the input shaft assembly.
   Fig 26: Installing Input Shaft Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 2 bearing races and needle roller bearing.
   Fig 27: Installing Bearing Races And Needle Roller Bearing

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the planetary ring gear.
   Fig 28: Installing Planetary Ring Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the ring gear flange.
   Fig 29: Installing Ring Gear Flange

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using a straight edge and vernier calipers, measure the dimension "A" and "B" correctly.
8. Select a shim that will ensure that the value is within the specification.

   Shim thickness: Dimension "B" - Dimension "A" 

   Fig 30: Measuring Dimension "A" and "B"

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   SHIM THICKNESS SPECIFICATIONS
   
   

   Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
   1	1.00 (0.0394)	7	2.20 (0.0866)
   2	1.20 (0.0472)	8	2.40 (0.0945)
   3	1.40 (0.0551)	9	2.60 (0.1024)
   4	1.60 (0.0630)	10	2.80 (0.1102)
   5	1.80 (0.0709)	11	3.00 (0.1181)
   6	2.00 (0.0787)	12	3.20 (0.1260)

9. Install the counter drive gear assembly to the MG1 assembly.
   Fig 31: Installing Counter Drive Gear Assembly To MG1 Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. Using a straight edge and vernier calipers, measure the dimension "A" and "B" correctly.
11. Select a shim thickness is surely within the specified range.

    Shim thickness: Dimension "B" - Dimension "A" 

Fig 32: Measuring Dimension "A" and "B"
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the shim selected in step 13 ( h).
   Fig 33: Installing Input Shaft Assembly To MG2 Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the ring gear flange.
Fig 34: Installing Ring Gear Flange, Races And Thrust Bearing
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the 2 races and thrust bearing.
   NOTE: Apply ATF to the thrust bearing.
4. Install the planetary ring gear.
   Fig 35: Installing Planetary Ring Gear

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the input shaft assembly.
   Fig 36: Installing Input Shaft Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the shim selected in step 13 ( k).
   Fig 37: Installing Shim

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the counter drive gear assembly and chain at the same time.
   Fig 38: Installing Counter Drive Gear Assembly And Chain

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Install the chain with the mark plate facing up.
3. Put the chain on the drive sprocket and install them.
   NOTE: Apply ATF to the drive sprocket needle roller bearing.
   Fig 39: Installing Chain On Drive Sprocket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the 2 bearing races and needle roller bearing.

Fig 40: Installing Bearing Races And Needle Roller Bearing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the lock sleeve.
   Fig 41: Installing Lock Sleeve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the cam guide sleeve to the sleeve bracket.
   Fig 42: Installing Cam Guide Sleeve To Sleeve Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the cam guide sleeve, sleeve bracket, torsion spring and 2 bolts.

   Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) 

   Fig 43: Installing Cam Guide Sleeve, Sleeve Bracket And Torsion Spring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install the parking lock pawl
5. Using a screw driver, fit the torsion spring into a cut-out of the parking lock pawl.
   Fig 44: Installing Parking Lock Pawl

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install the parking lock pawl shaft, lock clamp and bolt.

Torque: 5.4 N.m (55 kgf.cm, 48 in..lbf) 

Fig 45: Installing Parking Lock Pawl Shaft, Lock Clamp And Bolt

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install a new O-ring to the oil strainer.
   Fig 46: Installing O-Ring To Oil Strainer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the bolt and oil strainer.

   Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf) 

   Fig 47: Installing Bolt And Oil Strainer

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the magnet to the oil pan.
   Fig 48: Installing Magnet To Oil Pan

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Apply liquid sealer to 2 or 3 threads of the bolt end.

   Sealant: 

   Part No. 08833-00080, THREE BOND 2430, LOCTITE 204 or equivalent 

5. Install a new gasket and the oil pan with the 12 bolts.

   Torque: 7.6 N.m (77 kgf.cm, 67 in..lbf) 

6. Install a new gasket and drain plug.

   Torque: 49 N.m (498 kgf.cm, 36 ft.lbf) 

   Fig 49: Applying Liquid Sealer To Bolt End Threads

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply FIPG to the MG2 assembly as shown in Fig 50.
   Fig 50: Applying FIPG To MG2 Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   FIPG: 

   Part No. 08826 - 00090, THREE BOND 1281 or equivalent 

2. Install the MG1 to the MG2 (See REASSEMBLY ).
   NOTE: When putting MG2 and MG1 together, assemble them so that the parking rod is inserted into the cam guide sleeve.
   Fig 51: Inserting Parking Rod Into Cam Guide Sleeve

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Apply liquid sealer to 2 or 3 threads of the bolt end.

   Sealant: 

   Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent 

4. Install the 21 bolts.

   Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

   Fig 52: Applying Liquid Sealer To Bolt End Threads

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, install a new oil seal.
   Fig 53: Installing Input Shaft Oil Seal (MG1 Side)

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09388-40010

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

   NOTE: Drive in the oil seal unit SST comes into contact with the case.
2. Coat the lip of the oil seal with MP grease.

Set the hybrid transaxle assembly as shown in Fig 54.

Fig 54: View Of Hybrid Transaxle Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the parking lock lever No. 3 to the parking lock shaft.
2. Using a pin punch and a hammer, drive in the pin.
   Fig 55: Installing Pin

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Turn the spacer and the lever shaft to align the small hole in the spacer with the staking position mark on the lever shaft.
Fig 56: Aligning Small Hole In Spacer With Staking Position Mark On Lever Shaft
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a pin punch, stake the spacer through the small hole.
5. Check that the spacer does not turn.

1. Apply ATF to the parking lock shaft.
2. Apply MP grease to the parking lock lever No. 3.
3. Install the washer to the parking lock shaft assembly.
   Fig 57: Installing Washer To Parking Lock Shaft Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 58: Installing Parking Lock Shaft Assembly

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Using SST and a hammer, install a new oil seal to the parking shaft cover.
   Fig 59: Installing Oil Seal To Parking Shaft Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   SST 09950-60010 (09951-00230), 09950-70010 (09951-07100)

2. Coat the lip of the oil seal with MP grease.
3. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the parking shaft cover and MG2 case.
   • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
   • Thoroughly clean all components to remove all the loose material.
   • Using a non-reusable solvent, clean both sealing surfaces.
4. Apply FIPG to the parking shaft cover as shown in the illustration.

   FIPG: 

   Part No. 08826 - 00090, THREE BOND 1281 or equivalent 

   • Install a nozzle that has been cut to a 1.5 mm (0.06 in.) opening.
   • Parts must be assembled within 10 minutes after application. Otherwise the material must be removed and reapplied.
   • Remove the nozzle from the tube and reinstall the cap.
     Fig 60: Applying FIPG To Parking Shaft Cover

     Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the 5 bolts and parking shaft cover.
Fig 61: Installing Parking Shaft Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 13 N.m (130 kgf.cm, 10 ft.lbf) 

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the motor water jacket cover and MG2 case.
   • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
   • Thoroughly clean all components to remove all the loose material.
   • Using a non-reusable solvent, clean both sealing surfaces.
2. Apply FIPG to the motor water jacket cover as shown in Fig 62.
   Fig 62: Applying FIPG To Motor Water Jacket Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   FIPG: 

   Part No. 08826-00080 or equivalent 

   • Install a nozzle that has been cut to a 1.5 mm (0.06 in.) opening.
   • Parts must be assembled within 10 minutes after application. Otherwise the material must be removed and reapplied.
   • Remove the nozzle from the tube and reinstall the cap.
3. Apply liquid sealer to 2 or 3 threads of the bolt end.

   Sealant: 

   Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent 

4. Install the motor water jacket cover with the 6 bolts.

Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf) 

Fig 63: Applying Liquid Sealer To Bolt End Threads

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply liquid sealer to 2 or 3 threads of the housing tube end.
   Fig 64: Installing Housing Tube

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Sealant: 

   Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent 

2. Install the housing tube.

Torque: 15 N.m (152 kgf.cm, 11 ft.lbf) 

1. Install the detent spring and detent spring cover with the bolt.
   Fig 65: Installing Parking Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) 

2. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the parking cover and MG2 case.
   • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
   • Thoroughly clean all components to remove all the loose material.
   • Using a non-reusable solvent, clean both sealing surfaces.
3. Apply seal packing to the parking cover as shown in Fig 66.
   Fig 66: Applying Seal Packing To Parking Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   FIPG: 

   Part No. 08826 - 00090, THREE BOND 1281 or equivalent 

   • Install a nozzle that has been cut to a 1.5 mm (0.06 in.) opening.
   • Parts must be assembled within 10 minutes after application. Otherwise the material must be removed and reapplied.
   • Remove the nozzle from the tube and reinstall the cap.
4. Install the parking cover with the 6 bolts.
Fig 67: Installing Parking Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf) 

1. Apply ATF to individual sliding parts.
   Fig 68: Installing Oil Pump Drive Shaft

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the oil pump drive shaft.
3. Install the oil pump driven rotor and drive rotor.
   Fig 69: Installing Oil Pump Driven Rotor And Drive Rotor

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install a new O-ring without twisting it.
   Fig 70: Installing O-Ring

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Apply liquid sealer to 2 or 3 threads of the bolt end.
   Fig 71: Applying Liquid Sealer To Bolt End Threads

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Sealant: 

   Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent 

6. Install the oil pump cover with the 5 bolts.

   Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf) 

7. Install a new O-ring to the plug.
8. Install the plug.

Torque: 7.35 N.m (75 kgf.cm, 65 in..lbf) 

Fig 72: Installing O-Ring To Plug

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Install the 2 wiring harness connectors with the 2 bolts.

Fig 73: Installing Wiring Harness Connector (MG1 Side)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf) 

Install the wiring harness connectors with the bolt.

Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf) 

Fig 74: Installing Wiring Harness Connector (MG2 Side)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply liquid sealer to 2 or 3 threads of the union end.

   Sealant: 

   Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent 

2. Install the 4 water jacket unions.
Fig 75: Installing Water Jacket Unions
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 50 N.m (510 kgf.cm, 37 ft.lbf) 

1. Install the high-voltage cable with the 3 bolts.
   Fig 76: Installing High-Voltage Cable

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 18 N.m (183 kgf.cm, 13 ft.lbf) 

2. Apply liquid sealer to 2 or 3 threads of the bolt end.

   Sealant: 

   Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent 

3. Install the 3 bolts.
   Fig 77: Applying Liquid Sealer To Bolt End Threads

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 5.5 N.m (56 kgf.cm, 49 in..lbf) 

4. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the power cable cover and MG1 case.
   • Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
   • Thoroughly clean all components to remove all the loose material.
   • Using a non-reusable solvent, clean both sealing surfaces.
5. Apply FIPG to the power cable cover as shown in Fig 78.
   Fig 78: Applying FIPG To Power Cable Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   FIPG: 

   Part No. 08826 -00090, THREE BOND 1281 or equivalent 

   • Install the nozzle that has been cut to a 1.5 mm (0.06 in) opening.
   • Parts must be assembled within 10 minutes after application. Otherwise the material must be removed and reapplied.
   • Remove the nozzle from the tube and reinstall the cap.

   Torque: 4.8 N.m (48 kgf.cm, 42 in..lbf) 

6. Install the power cable cover with the 4 bolts.
Fig 79: Installing Power Cable Cover
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Apply liquid sealer to 2 or 3 threads of the bolt end.

   Sealant: 

   Part No. 08833 - 00070, THREE BOND 1324 or equivalent 

2. Install the mounting bracket with the 3 bolts.
   Fig 80: Installing Mounting Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)