22 - Hybrid Transaxle.pdf

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22–1
HYBRID TRANSAXLE
–
HYBRID TRANSAXLE SYSTEM
HYBRID TRANSAXLE SYSTEM
ON–VEHICLE INSPECTION
2200U–01
1. CHECK TRANSAXLE FLUID LEVEL
NOTICE:
Insufficient or excessive amounts of transaxle oil
may be the cause of some trouble.
Stop the vehicle on a flat road.
Use genuine ATF WS.
(a) Remove the filler plug.
(b) Ensure that there is transaxle oil within 0 to 5 mm of the
filler plug hole.
NOTICE:
Recheck the transaxle oil level after driving when exchang-
ing oil.
HINT:
Transaxle fluid quantity: 3.8 L (4.0 USqts, 3.3 Imp. qts.)
(c)
Filler Plug
Drain Plug
Check for leaks if the quantity of oil is low.
G30993
G30260
(d)
Install the filler plug using a new gasket.
Torque: 39 N
V
m (400 kgf
V
cm, 29 ft
V
lbf)
2. INSPECT OIL PRESSURE IN OIL PUMP
NOTICE:
Do 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
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).
SST
(f)
Keeping the engine speed of 1,200 rpm, measure the oil
pressure.
Oil pressure: 9.8 kPa (0.1 kgf/cm 2 , 1.4 psi) or more
G30394
2004 Prius – Preliminary Release (RM1075U)
Author:
Date:
473
825332960.006.png 825332960.007.png
22–2
HYBRID TRANSAXLE
–
HYBRID TRANSAXLE SYSTEM
(g)
Install a new O–ring and fluid pump cover plug.
Torque: 7.4 N
V
m (75 kgf
V
cm, 65 in.
V
lbf)
G30396
3. INSPECT SHIFT LEVER
(a) Inspect with the hybrid system started up
(1) Insert the key into the key slot.
(2) Carry the key with you or insert the key in the key
slot (vehicles equipped with smart entry and start
system)
(3) Turn the power switch on (READY ON) while de-
pressing the brake pedal.
Check if gears change according to the shift operation pattern.
If the check result is abnormal, replace the shift lever assy.
HINT:
The shift operation pattern in READY ON (when the vehicle is
stopped) is shown below.
Key slot
Turn the power switch on
C97702
Z35573
2004 Prius – Preliminary Release (RM1075U)
Author:
Date:
474
825332960.008.png 825332960.001.png
22–3
HYBRID TRANSAXLE
–
HYBRID TRANSAXLE SYSTEM
(b)
Turn the power switch off when stopping.
Power switch
G21872
(c)
Inspect with the power condition IG
HINT:
All electrical components operate but the hybrid system does
not start–up.
(1)
Key slot
Insert the key into the key slot.
(2)
Carry the key with you or insert the key in the key
slot (vehicles equipped with smart entry and start
system)
C97718
G30999
(d)
Turn the power switch on once without depressing the
brake pedal.
Turn the power switch on without de-
pressing the brake pedal.
HINT:
This condition switches between OFF, ACC and IG each time
the power switch is pressed.
Check if gears change according to the shift operation pattern.
If the check result is abnormal, replace the shift lever assy.
HINT:
The shift operation pattern in power condition IG is shown be-
low.
Power switch
G30998
G21873
Z35574
2004 Prius – Preliminary Release (RM1075U)
Author:
Date:
475
825332960.002.png 825332960.003.png
22–4
HYBRID TRANSAXLE
–
COOLANT
COOLANT
REPLACEMENT
1.
2200V–01
REMOVE ENGINE UNDER COVER LH
2.
REMOVE ENGINE UNDER COVER RH
3. DRAIN COOLANT
(a) Remove the transaxle–side reserve tank cap.
NOTICE:
Do not remove the reserve tank cap when the engine is hot.
(b)
Remove the plug shown in the illustration and drain the
coolant.
(c)
Install the plug using a new gasket.
Torque: 39 N
V
m (400 kgf
V
cm, 29 ft
V
lbf)
C98375
4. ADD COOLANT
(a) Loosen the bleeder plug shown in the illustration and con-
nect a hose.
NOTICE:
Insert one end of the hose into the bleeder tank.
(b) Add coolant from the bleeder tank.
NOTICE:
Add genuine Toyota Super LLC coolant.
C98376
(c)
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.
(d)
Close the bleeder plug.
(e)
Turn the power switch on (ON) and run the water pump
for approximately 20 seconds before pushing the power
switch off. (*1)
(f)
Loosen the bleeder plug and bleed the air from within the
transaxle after turn the power switch off. Close the bleed-
er plug again. (*2)
C98377
(g)
Add coolant from the bleeder tank. (*3)
(h)
Add coolant by repeating *1, *2 and *3.
Standard:
Air bleeding from the coolant system is completed
when the noise made by the water pump becomes
smaller and the circulation of coolant in the reserve
tank improves.
2004 Prius – Preliminary Release (RM1075U)
Author:
Date:
476
825332960.004.png
22–5
HYBRID TRANSAXLE
–
COOLANT
HINT:
Loud noise made by the water pump and poor circulation of
coolant in the reserve tank indicates that there is air in the cool-
ant system.
(i) Turn the power switch on (ON) 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.
(j)
Add coolant until the reserve tank is filled to the FULL
mark.
C98378
5.
CHECK FOR ENGINE COOLANT LEAKS (SEE PAGE 16–4 )
2004 Prius – Preliminary Release (RM1075U)
Author:
Date:
477
825332960.005.png

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