P610 (HYBRID TRANSMISSION / TRANSAXLE): HYBRID VEHICLE TRANSAXLE: REMOVAL; 2020 MY Corolla Corolla HV [01/2019

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM100000001H6SW
Model Year Start: 2020	Model: Corolla	Prod Date Range: [01/2019 - 04/2020]
Title: P610 (HYBRID TRANSMISSION / TRANSAXLE): HYBRID VEHICLE TRANSAXLE: REMOVAL; 2020 MY Corolla Corolla HV [01/2019 - 04/2020]

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during hybrid vehicle transaxle assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Lane Control System (for HV Model)
Auxiliary battery terminal is disconnected/reconnected	Perform steering sensor zero point calibration	Pre-collision System (for HV Model)
Replacement of ECM	Vehicle Identification Number (VIN) or frame number registration	MIL comes on
Replacement of inverter with converter assembly	Resolver learning	DTCs are stored Slight vibration at a vehicle speed of 5 km/h (3 mph) or less Shock or vibration during acceleration
Replacement of hybrid vehicle transaxle assembly	Resolver learning Initialize resolver
Replacement of throttle body assembly Replacement of engine assembly Gas leak from exhaust system is repaired	Inspection After Repair	Poor idle, etc. Engine start function, etc.
Front wheel alignment adjustment	Clear zero point calibration data Perform yaw rate and acceleration sensor zero point calibration	DTCs are stored ABS warning light illuminates Brake warning light / yellow (minor malfunction) illuminates Slip indicator light illuminates VSC disabled or malfunctions

CAUTION:

This vehicle has contains high voltage circuits standardized with orange colored wiring and connectors, so follow the instructions in this manual to perform the procedures correctly.
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If the correct procedures are not followed according to the instructions in this manual, there is a danger of electric shock from the high voltage circuits.
Be sure to wear insulating gloves when working on high voltage wiring or components.
If work is performed without wearing insulating gloves, there is a danger of electric shock.
To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.

*a	An Object Exceeding Weight Limit of Engine Lifter

NOTICE:

After the power switch is turned off, the radio and display receiver assembly records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 85 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal. (for Audio and Visual System (for HV Model))

PROCEDURE

1. PERFORM RESOLVER INITIALIZATION

NOTICE:

If it is necessary to replace the hybrid vehicle transaxle assembly, make sure to perform resolver initialization before starting work.

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2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

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3. REMOVE WIRE HARNESS CLAMP BRACKET

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4. INSTALL ENGINE HANGERS

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5. DISCONNECT ENGINE WIRE

(a) Disconnect the motor resolver, generator resolver and transmission fluid temperature sensor connector.

*a	Motor Resolver, Generator Resolver and Transmission Fluid Temperature Sensor Connector	*b	Motor Temperature Sensor and Generator Temperature Sensor Connector
*c	Shift Lever Position Sensor Connector	-	-

(b) Disconnect the motor temperature sensor and generator temperature sensor connector.

NOTICE:

After disconnecting the engine wire, cover the connector of the shift lever position sensor with tape (non-residue type) or equivalent to prevent the entry of foreign matter or water.

(d) Remove the 2 bolts.

(e) Disengage the 2 clamps to disconnect the engine wire from the hybrid vehicle transaxle assembly.

6. DISCONNECT HV AIR CONDITIONING WIRE

(a) Remove the bolt.

(b) Disengage the guide to disconnect the HV air conditioning wire from the hybrid vehicle transaxle assembly.

7. REMOVE STARTER HOLE INSULATOR

(a) Remove the 2 bolts and starter hole insulator from the engine assembly.

8. REMOVE FLYWHEEL HOUSING SIDE COVER

(a) Remove the flywheel housing side cover from the engine assembly.

9. REMOVE ENGINE ASSEMBLY

(a) Remove the 7 bolts and engine assembly from the hybrid vehicle transaxle assembly.

NOTICE:

To avoid damaging the knock pins, do not pry between the hybrid vehicle transaxle assembly and engine assembly.
To prevent the splines of the transmission input damper assembly from becoming misaligned, do not allow the hybrid vehicle transaxle assembly to hit the transmission input damper assembly during engine assembly removal and installation.

10. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Remove the bolt and front suspension crossmember sub-assembly from the No. 2 engine moving control rod.

11. REMOVE NO. 2 ENGINE MOVING CONTROL ROD

(a) Remove the 4 bolts and No. 2 engine moving control rod from the hybrid vehicle transaxle assembly.

12. REMOVE MOTOR CABLE

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13. REMOVE MOTOR COOLING COOLER

(a) Slide the clip and disconnect the No. 1 motor cooling hose from the No. 1 motor cooling pipe.

(b) Remove the bolt and No. 1 oil cooler tube clamp from the hose bracket.

(c) Remove the union bolt and gasket to disconnect the No. 2 motor cooling pipe from the hybrid vehicle transaxle assembly.

(d) Remove the 3 bolts and motor cooling cooler with No. 2 motor cooling pipe from the hybrid vehicle transaxle assembly.

NOTICE:

Make sure not to remove the No. 1 motor cooling hose and No. 2 motor cooling hose from the motor cooling cooler as the motor cooling cooler may be deformed.

14. REMOVE NO. 1 MOTOR COOLING PIPE

(a) Loosen the flare nut of the No. 1 motor cooling pipe and disconnect the No. 1 motor cooling pipe from the union.

(b) Remove the bolt, No. 1 oil cooler tube clamp and No. 1 motor cooling pipe from the hose bracket.

15. REMOVE HOSE BRACKET

(a) Remove the 2 bolts and hose bracket from the hybrid vehicle transaxle assembly.

16. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET

(a) Remove the 2 bolts and No. 1 transmission control cable bracket from the hybrid vehicle transaxle assembly.

17. REMOVE WIRE HARNESS CLAMP BRACKET

(a) Remove the 2 bolts and 2 wire harness clamp brackets from the hybrid vehicle transaxle assembly.

18. REMOVE TRANSAXLE HOUSING PLUG

(a) Remove the transaxle housing plug and gasket from the hybrid vehicle transaxle assembly.

19. REMOVE STUD BOLT

(a) Using a E8 "TORX" socket wrench, remove the 2 stud bolts from the hybrid vehicle transaxle assembly.