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Hybrid Transaxle Assembly: Reassembly

  1. Inspect rotor bush of MG2 assembly  .

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

    Fig 1: Measuring Rotor Brush Diameter
    G01065987Courtesy 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.

  2. Place wood block under MG1 assembly to stabilize  .
    Fig 2: Placing Wooden Blocks Under Motor Generator No. 1 Assembly
    G01065988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. Install drain plug and screw plug (MG1 Side)  :
    1. Apply liquid sealer to the screw plug and install it to the MG1 assembly with a hexagon wrench.

      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.
      Fig 3: Identifying Drain & Screw Plugs (MG1 Assembly)
      G01065989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    4. CAUTION: Be careful not to bend the parking lock rod.
    Fig 4: Repositioning Motor Generator No. 2 On Wooden Blocks
    G01065990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. Place wood block under MG2 assembly  .
  5. Install filler plug and screw plug (MG2 side)  :
    1. Apply liquid sealer to the 2 screw plugs and install them to the MG2 assembly with a hexagon wrench.

      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)  .

      2. CAUTION: Be careful not to bend the parking lock rod.
      Fig 5: Identifying Filler Plugs & Screw Plugs (MG2 Side)
      G01065991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install 2 new gaskets and the 2 filler plugs.

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

  6. Install differential oil seal RH (MG1 Side)  :
    1. Using SST and a hammer, install a new oil seal.
      Fig 6: Installing Right Side Differential Oil Seal (MG1 Assembly)
      G01065992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09710-20011 (09710-06071), 09950-70010 (09951-07100).

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

    2. Coat the lip of the oil seal with MP grease.
  7. Install differential oil seal LH (MG2 Side)  :
    1. Using SST and a hammer, install a new oil seal LH.
      Fig 7: Installing Right Side Differential Oil Seal (MG2 side)
      G01065993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      SST 09710-20011 (09710-06071), 09950-70010 (09951-07100)

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

    2. Coat the lip of the oil seal with MP grease.
  8. Install breather plug  .
    Fig 8: Locating Breather Plug
    G01065994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    9. NOTE: If there is some deformation or scratch to the outer race and shim, replace each of them by a new one.
  9. Install outer race and shim  :
      NOTE:
      • Set the MG2 assembly horizontally.
      • Unreasonable force should not be applied to the high-voltage cable.
      Fig 9: Repositioning Motor Generator No. 2 On Wooden Blocks
      G01065995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Place a wood block under the MG2 assembly to stabilize.
      2. NOTE: If replacing the shim, install a new shim which has the same thickness with the removed.
      Fig 10: Installing Left Side Differential Side Bearing Outer Race
      G01065996Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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).
      3. NOTE: If replacing the shim, install a new shim which has the same thickness with the removed.
      Fig 11: Installing Left Side Counter Driven Gear Tapered Roller Bearing Outer Race (MG2 Assembly)
      G01065997Courtesy 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).
    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 Differential Side Bearing Outer Race (MG1 Assembly)
      G01065998Courtesy 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 Right Side Counter Driven Gear Tapered Roller Bearing Outer Race (MG1 Assembly)
      G01065999Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. Install differential to MG2 assembly  :
      NOTE: Apply ATF to the side bearing.
      Fig 14: Identifying Differential Case Assembly
      G01066000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the differential assembly to the MG2 assembly.
    2. Install the engine hanger onto the MG1 side as shown in the illustration, and lift it up by a chain device.
      Fig 15: Mounting Engine Hanger
      G01066001Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Engine hanger part No.  12281-67070, S1228-11781.
      2. Bolt part No.  91642-81045, 91642-81265 2 pieces.
      3. Nut part No.  90178-10001, 90179-12147 2 pieces.
    3. Install the 13 bolts and MG1 assembly to the MG2 assembly.

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

      Fig 16: Installing MG1 & MG2 Assemblies Using 13 Bolts
      G01066002Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, rotate the differential case assembly in both directions to make it fit. SST 09564-32011.
      Fig 17: Rotating Differential Case Assembly
      G01066003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST and a small torque wrench, measure the differential preload. SST 09564-32011.
      Fig 18: Determining Differential Case Assembly Preload
      G01066004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Preload (Starting torque)

      1. New bearing  0.98 - 1.57 N.m, (9.99 - 16.01 kgf.cm, 8.67 - 13.90 in.lbf).
      2. Reused bearing:  0.49 - 0.78 N.m, (5.00 - 7.95 kgf.cm, 4.34 - 6.90 in.lbf).
      3. 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.

    NOTE: As a rank of shim thickness is increased (0.020 mm), the preload of approximately 0.23 N.m (2.4 kgf.cm, 2.1 in.lbf) is increased accordingly.
    Fig 19: Differential Outer Race Shim Thickness Specifications
    G01066005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. Install counter driven gear to MG2 assembly  :
    1. Remove the 13 bolts, separate the MG1 assembly and the MG2 assembly.
      2. NOTE: Apply ATF to the side bearing.
      Fig 20: Identifying Counter Driven Gear & Differential Case Assembly
      G01066006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the counter driven gear to the MG2 assembly.
    3. Install the engine hanger onto the MG1 side as shown in Fig 21, and lift it up by a chain device.
      Fig 21: Mounting Engine Hanger
      G01066007Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Engine hanger part No.  12281-67070, S1228-11781.
      2. Bolt part No.  91642-81045, 91642-81265 2 pieces.
      3. Nut part No.  90178-10001, 90179-12147 2 pieces.
    4. Install the MG1 assembly to the MG2 assembly with the 13 bolts.

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

      Fig 22: Installing MG1 & MG2 Assemblies Using 13 Bolts
      G01066008Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, rotate the differential case assembly in both directions to make it fit.

      SST 09564-32011.

      Fig 23: Rotating Differential Case Assembly
      G01066009Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using SST and a small torque wrench, measure the counter driven gear preload. SST 09564-32011.
      Fig 24: Determining Counter Driven Gear Preload By Rotating Differential Case Assembly
      G01066010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

    NOTE: As a rank of shim thickness is increased (0.020 mm) the preload of approximately 1.1 N.m (11.2 kgf.cm, 9.7 in.lbf) is increased accordingly.
    Fig 25: Counter Driven Gear Shim Thickness Specifications
    G01066011Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. Remove 13 bolts, separate MG1 assembly and MG2 assembly  :
  13. Adjust shim  :
    1. Install the 2 bearing races and needle roller bearing to the MG1 assembly.
      Fig 26: Identifying Drive Sprocket To Input Shaft 2 Races & Needle Roller Bearing (MG1 assembly)
      G01066012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the drive sprocket assembly to the MG1 assembly.
      Fig 27: Identifying Drive Sprocket (MG1 assembly)
      G01066013Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the input shaft assembly.
      Fig 28: Identifying Input Shaft Assembly (MG1 assembly)
      G01066014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the 2 bearing races and needle roller bearing.
      Fig 29: Identifying Input Shaft To Ring Gear 2 Races & Needle Roller Bearing (MG1 assembly)
      G01066015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the planetary ring gear.
      Fig 30: Identifying Planetary Ring Gear (MG1 assembly)
      G01066016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the ring gear flange.
      Fig 31: Installing Ring Gear Flange (MG1 assembly)
      G01066017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a straight edge and vernier calipers, measure the dimension "A" and "B" correctly.
      Fig 32: Calculating Input Shaft Assembly Measurements A & B (MG1 assembly)
      G01066019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Select a shim that will ensure that the value is within the specification.

      Shim thickness: 

      Dimension "B" - Dimension "A"  .

      Fig 33: Input Shaft Shim Thickness Chart (MG1 assembly)
      G01066018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Install the counter drive gear assembly to the MG1 assembly.
      Fig 34: Installing Counter Drive Gear (MG1 assembly)
      G01066020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Using a straight edge and vernier calipers, measure the dimension "A" and "B" correctly.
      Fig 35: Calculating Counter Drive Gear Measurements A & B (MG1 assembly)
      G01066022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Select a shim thickness is surely within the specified range.

      Shim thickness: 

      Dimension "B" - Dimension "A"  .

      Fig 36: Counter Drive Gear Shim Thickness Chart (MG1 assembly)
      G01066021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. Install input shaft assembly to MG2 assembly 
    1. Install the shim selected in step 13 ( h).
      Fig 37: Installing Input Shaft Assembly Shim (MG2 assembly)
      G01066023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the ring gear flange.
      3. NOTE: Apply ATF to the thrust bearing.
      Fig 38: Exploded View Of Ring Gear Flange, Thrust Bearing & Races (MG2 assembly)
      G01066024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 2 races and thrust bearing.
    4. Install the planetary ring gear.
      Fig 39: Installing Planetary Ring Gear (MG2 assembly)
      G01066025Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the input shaft assembly.
      Fig 40: Identifying Input Shaft (MG2 assembly)
      G01066026Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. Install counter drive gear assembly, chain and drive sprocket assembly  :
    1. Install the shim selected in step 13 ( k).
      Fig 41: Installing Counter Drive Gear Assembly Shim (MG2 Assembly)
      G01066027Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. NOTE: Install the chain with the mark plate facing up.
      Fig 42: Locating Counter Drive Gear Chain Mark Plate (MG2 assembly)
      G01066028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the counter drive gear assembly and chain at the same time.
      3. NOTE: Apply ATF to the drive sprocket needle roller bearing.
      Fig 43: Install Counter Drive Gear & Chain (MG2 assembly)
      G01066029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Put the chain on the drive sprocket and install them.
      4. NOTE: Apply ATF to the thrust bearing.
    4. Install the 2 bearing races and needle roller bearing.
    Fig 44: Identifying Input Shaft To Ring Gear 2 Races & Needle Roller Bearing (MG2 assembly)
    G01066030Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. Install parking lock pawl to MG1 assembly  .
    1. Install the lock sleeve.
      Fig 45: Installing Lock Sleeve
      G01066031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the cam guide sleeve to the sleeve bracket.
      Fig 46: Identifying Cam Guide Sleeve & Sleeve Bracket
      G01066032Courtesy 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 47: Locating Parking Lock Sleeve, Sleeve Bracket & Mounting Bolts
      G01066033Courtesy 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 48: Installing Torsion Spring To Parking Pawl
      G01066034Courtesy 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 49: Identifying Lock Clamp Bolt
      G01066035Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. Install oil pan (MG2 side)  :
    1. Install a new "O" ring to the oil strainer.
      Fig 50: Identifying Transaxle Oil Strainer & "O" Ring
      G01066036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the bolt and oil strainer.

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

      Fig 51: Identifying Transaxle Oil Strainer Bolt
      G01066037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the magnet to the oil pan.
      Fig 52: Locating Oil Pan Magnet
      G01066038Courtesy 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)  .

  18. Install MG1 assembly to MG2 assembly  :
    1. Apply FIPG to the MG2 assembly as shown in the illustration.

      FIPG: 

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

    2. Install the MG1 to the MG2. See Reassembly .
      Fig 53: Identifying Seal Packing Application Points
      G01066040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: When putting MG2 and MG1 together, assemble them so that the parking rod is inserted into the cam guide sleeve.
      Fig 54: Ensuring Alignment Pin Meets Female Counterpart
      G01066041Courtesy 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 55: Identifying MG1 To MG2 Mounting Bolts
      G01066042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. Install oil seal of input shaft (MG1 side) 
    1. Using SST and a hammer, install a new oil seal.

      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.
      Fig 56: Installing Oil Seal & Identifying Installation Depth (MG1 Assembly)
      G01066043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. Set hybrid transaxle assembly  :

    Set the hybrid transaxle assembly as shown in the illustration.

    Fig 57: Positioning Hybrid Transaxle Assembly To Required Orientation
    G01066044Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. Reassemble parking lock shaft assembly  .
    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 58: Pin Punching Parking Lock Shaft Roll Pin
      G01066045Courtesy 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.
    4. Using a pin punch, stake the spacer through the small hole.
    5. Check that the spacer does not turn.
      Fig 59: Aligning & Staking Spacer
      G01066046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. Install parking lock shaft assembly and washer  :
    1. Apply ATF to the parking lock shaft.
      Fig 60: Identifying Lubricant Application Points For Steps A & B
      G01066047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply MP grease to the parking lock lever No. 3.
    3. Install the washer to the parking lock shaft assembly.
  23. Install parking lock shaft assembly  :
    Fig 61: Locating Parking Lock Shaft
    G01066048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using SST and a hammer, install a new oil seal to the parking shaft cover.
      Fig 62: Installing Parking Shaft Cover Oil Seal
      G01066049Courtesy 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.
      Fig 63: Installing Parking Shaft Cover Seal Packing Application Points
      G01066050Courtesy 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.
    5. Install the 5 bolts and parking shaft cover.

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

    NOTE: When installing the cover, be careful not to damage the lip of the oil seal.
  24. Install motor water jacket cover  :
    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.
        Fig 64: Identifying Parking Shaft Cover
        G01066051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Apply FIPG to the motor water jacket cover as shown in the illustration.

      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.
        Fig 65: Applying Seal Packing To Motor Generator 2 Water Jacket Cover
        G01066052Courtesy 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 motor water jacket cover with the 6 bolts.

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

      Fig 66: Identifying Motor Generator 2 Water Jacket Cover & Bolts
      G01066053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. Install housing tube  :
    1. Apply liquid sealer to 2 or 3 threads of the housing tube end.

      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)  .

      Fig 67: Identifying Housing Tube (MG1 Assembly)
      G01066054Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. Install parking cover  :
    1. Install the detent spring and detent spring cover with the bolt.

      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.
        Fig 68: Install Detent Spring & Cover
        G01066055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply seal packing to the parking cover as shown in Fig 69.

      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 69: Seal Packing
        G01066056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the parking cover with the 6 bolts.

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

      Fig 70: Identifying Parking Cover & Bolts
      G01066057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. Install oil pump  :
    1. Apply ATF to individual sliding parts.
    2. Install the oil pump drive shaft.
      Fig 71: Identifying Oil Pump Drive Shaft
      G01066058Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the oil pump driven rotor and drive rotor.
      Fig 72: Identifying Oil Pump Driven Rotor & Drive Rotor
      G01066059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install a new "O" ring without twisting it.
      Fig 73: Identifying Oil Pump Cover "O" Ring
      G01066060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply liquid sealer to 2 or 3 threads of the bolt end.

      Sealant: 

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

    6. Install the oil pump cover with the 5 bolts.
      Fig 74: Identifying Oil Pump Cover & Bolts
      G01066061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 75: Identifying Oil Pump Cover Plug & Plug "O" Ring
      G01066062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. Install wiring harness connector (MG2 side) 

    Install the 2 wiring harness connectors with the 2 bolts.

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

    Fig 76: Identifying Wiring Harness Connectors (MG2 Side)
    G01066063Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. Install wiring harness connector (MG1 Assembly) 

    Install the wiring harness connector with the bolt.

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

    Fig 77: Identifying Wiring Harness Connectors (MG1 Assembly)
    G01066064Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. Install 4 water jacket unions  :
    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.

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

      Fig 78: Identifying Water Jacket Unions (MG1 & MG2 Sides)
      G01066065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. Install high-voltage cable  :
    1. Install the high-voltage cable with the 3 bolts.

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

      Fig 79: Identifying High Voltage Cable Terminal Bolts
      G01066066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.

      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.
        Fig 80: Identifying High Voltage Cable Securing & Terminal Bolts
        G01066067Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Apply FIPG to the power cable cover as shown in the illustration.

      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.
        Fig 81: Applying Seal Packing To Power Cable Cover
        G01066068Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Install the power cable cover with the 4 bolts.

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

      Fig 82: Locating Power Cable Cover Bolts
      G01066069Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. Install mounting bracket  :
    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 83: Locating Motor Generator 2 Mounting Bracket Bolts
      G01066070Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

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