ENGINE ASSEMBLY 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 engine assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link
Disconnect cable from negative auxiliary battery terminal Memorize steering angle neutral point Lane departure alert system (w/ Steering Control)

Click here

Simple intelligent parking assist system*1
Toyota parking assist-sensor system*1
Pre-collision system
Initialize back door lock Power door lock control system

Click here

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

Click here


    for SFI system

  • Replacement of ECM

 Perform Vehicle Identification Number (VIN) or frame number registration MIL comes on

Click here


    for SFI system

  • 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.

Click here

Suspension, tires, etc.

(The vehicle height changes because of suspension or tire replacement)

 Initialize No. 1 headlight ECU sub-assembly LH Automatic headlight beam level control system

Click here

Front wheel alignment adjustment

  1. Clear zero point calibration data.

  2. 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

for Initialization:

Click here

for Calibration:

Click here

Replacement of hybrid vehicle transaxle assembly

  • Resolver learning

  • Initialize resolver

  • DTCs are stored

  • Slight vibration at a vehicle speed of 5 km/h (3 mph) or less

  • Shock or vibration during acceleration

Click here

*1: When performing learning using the GTS.

Click here

CAUTION:


  • A001OG1C01
    *a An Object Exceeding Weight Limit of Engine Lifter

    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.

  • A001RVS

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

PROCEDURE


  1. PRECAUTION

    CAUTION:

    The vehicle has a hybrid system that operates at voltages up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this manual to handle the system correctly. Failure to do so may result in serious injury or electrocution.

    Click here

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

    Click here

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  3. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  5. SECURE STEERING WHEEL ASSEMBLY

    Click here

  6. REMOVE FRONT WHEELS

    Click here

  7. REMOVE NO. 1 ENGINE UNDER COVER


    1. A005NX5

      Remove the 4 bolts, 4 screws, 4 clips and No. 1 engine under cover from the vehicle.

  8. REMOVE REAR ENGINE UNDER COVER LH


    1. A001POC

      Remove the 6 clips and rear engine under cover LH from the vehicle.

  9. REMOVE REAR ENGINE UNDER COVER RH


    1. A001OQT

      Remove the 6 clips and rear engine under cover RH from the vehicle.

  10. DRAIN ENGINE OIL

    Click here

  11. DRAIN ENGINE COOLANT (for Engine)

    Click here

  12. DRAIN HYBRID TRANSAXLE FLUID

    Click here

  13. DISCONNECT NO. 8 WATER BY-PASS HOSE


    1. A001QVN

      Slide the clip and disconnect the No. 8 water by-pass hose from the No. 2 water by-pass hose assembly.

  14. REMOVE RADIATOR COVER

    Click here

  15. REMOVE NO. 2 AIR CLEANER INLET

    Click here

  16. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  17. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  18. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  19. REMOVE AIR CLEANER BRACKET

    Click here

  20. REMOVE NO. 1 AIR CLEANER INLET

    Click here

  21. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

  22. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A001QE8

      Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.

    2. Remove the clip and disconnect the transmission control cable assembly from the No. 1 transmission control cable bracket.

    3. A001OMJ

      Remove the bolt to disconnect the transmission control cable assembly from the cylinder head cover sub-assembly.

  23. DISCONNECT NO. 3 RADIATOR HOSE


    1. A001PKJ

      Remove the 2 bolts from the hybrid vehicle transaxle assembly.

    2. Slide the clip and disconnect the No. 3 radiator hose from the water outlet.

  24. DISCONNECT NO. 2 RADIATOR HOSE


    1. A001RYI

      Slide the clip and disconnect the No. 2 radiator hose from the water inlet sub-assembly.

  25. DISCONNECT OUTLET HEATER WATER HOSE


    1. A001O65

      Slide the clip and disconnect the outlet heater water hose from the No. 1 water by-pass pipe.

  26. DISCONNECT INLET HEATER WATER HOSE A


    1. A001Q0W

      Slide the clip and disconnect the inlet heater water hose A from the EGR pipe with cooler sub-assembly.

  27. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. A001PPA

      Slide the clip and disconnect the No. 1 fuel vapor feed hose from the fuel vapor feed pipe.

  28. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  29. DISCONNECT INLET HYBRID RADIATOR HOSE


    1. A001O4X

      Slide the clip and disconnect the inlet hybrid radiator hose from the motor cooling cooler.

  30. DISCONNECT OUTLET NO. 1 HYBRID WATER PUMP HOSE


    1. A001RFR

      Slide the clip and disconnect the outlet No. 1 hybrid water pump hose from the motor cooling cooler.

  31. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  32. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  33. DISCONNECT NO. 3 ENGINE WIRE


    1. A005MYU

      Disengage the clamp.

    2. Remove the 2 bolts and disconnect the No. 3 engine wire from the hybrid vehicle transaxle assembly.

  34. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  35. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  36. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  37. REMOVE FRONT FLOOR COVER LH

    Click here

  38. REMOVE FRONT FLOOR COVER RH

    Tech Tips

    Use the same procedure as for the LH side.

  39. REMOVE FRONT FLOOR CENTER BRACE

    Click here

  40. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

    Click here

  41. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  42. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  43. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  44. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine assembly with transaxle on an engine lifter.

      Note


      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle and front suspension crossmember sub-assembly level.

      • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

      • To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.

      • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

    2. A001PG0

      Remove the 2 bolts and nut and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.

    3. A001OW7

      Remove the 3 bolts and nut and separate the engine mounting insulator LH from the hybrid vehicle transaxle assembly.

    4. A001QHB

      Remove the bolt and No. 2 engine mounting stay LH.

    5. A001RZB

      Remove the 6 bolts to separate the front suspension crossmember sub-assembly from the vehicle.

    6. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.

      Note


      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

      • While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.

  45. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A001Q6S

      Disengage the 3 clamps.

    2. Remove the bolt and wire harness clamp bracket from the cylinder head sub-assembly.

  46. INSTALL ENGINE HANGERS


    1. A001R0PC01
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      *3 Bolt

      Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-37021
      No. 2 Engine Hanger 12282-37011
      Bolt 91552-81050

    2. Using an engine sling device and engine lifter, secure the engine assembly with transaxle.

      Note


      • Adjust the angle of the sling device carefully to prevent damage or deformation to the engine hangers or engine assembly.

      • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

  47. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator LH is necessary.


    1. A005MUD

      Remove the 4 bolts, nut and engine mounting insulator LH from the vehicle.

  48. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.


    1. A001PTS

      Remove the 2 bolts and No. 2 earth wire from the engine mounting insulator sub-assembly RH and vehicle.

    2. A005MNO

      Remove the bolt, nut and disconnect the air conditioner tube and accessory assembly.

    3. Remove the 2 bolts, nut and engine mounting insulator sub-assembly RH from the vehicle.

  49. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  50. REMOVE STARTER HOLE INSULATOR

    Click here

  51. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  52. REMOVE ENGINE WIRE


    1. Disconnect all the clamps and connectors and remove the engine wire from the engine assembly with transaxle.

  53. REMOVE ENGINE ASSEMBLY

    Click here

  54. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

    Click here

  55. REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  56. INSTALL ENGINE ASSEMBLY TO ENGINE STAND


    1. Install the engine assembly to an engine stand.

  57. REMOVE ENGINE HANGERS


    1. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.