ENGINE ASSEMBLY REMOVAL

PROCEDURE


  1. PRECAUTION

    CAUTION:


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

    • 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. REMOVE ENGINE ROOM SIDE COVER

    Click here

  3. REMOVE COOL AIR INTAKE DUCT SEAL

    Click here

  4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. B004F8JC02
      *a When detaching the clip on the rear side of the No. 1 engine cover sub-assembly.
      B004FO9 Areas to be Held when Lifting No. 1 Engine Cover Sub-assembly

      Hold the areas of the No. 1 engine cover sub-assembly shown in the illustration and lift the No. 1 engine cover sub-assembly to disengage the front clips (1) and (2).

    2. With the No. 1 engine cover sub-assembly raised, disengage the rear clip (3) and remove the No. 1 engine cover sub-assembly.

      Note


      • Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover sub-assembly to break.

      • If the procedures are not followed exactly, the rear clip may be damaged.

      • Attempting to disengage the No. 1 engine cover sub-assembly with only one of the front clips detached may result in damage to the No. 1 engine cover sub-assembly.

  5. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    for HFC-134a(R134a): Click here

    for HFO-1234yf(R1234yf): Click here

  6. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  7. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  8. SECURE STEERING WHEEL

    Click here

  9. REMOVE FRONT WHEELS

    Click here

  10. REMOVE SERVICE PLUG GRIP

    Click here

  11. REMOVE CONNECTOR COVER ASSEMBLY

    Click here

  12. CHECK TERMINAL VOLTAGE

    Click here

  13. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

    Click here

  14. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY


    1. B004FEM

      Remove the 13 screws, 3 clips and No. 1 engine under cover assembly.

  15. REMOVE REAR ENGINE UNDER COVER LH


    1. B004GON

      Remove the screw and rear engine under cover LH.

  16. REMOVE REAR ENGINE UNDER COVER RH

    Tech Tips

    Use the same procedure as for the LH side.

  17. REMOVE FRONT SUSPENSION MEMBER BRACE


    1. B004ETX

      Remove the 4 bolts, turn the clip to loosen it, and remove the front suspension member brace.

      Tech Tips

      Do not remove the clip from the front suspension member brace.

  18. REMOVE NO. 2 ENGINE UNDER COVER


    1. B004F59C01
      *1 Grommet

      Remove the 4 screws, turn the 2 grommets to loosen them and remove the No. 2 engine under cover.

  19. DRAIN ENGINE OIL

    Click here

  20. DRAIN ENGINE COOLANT (for Engine)

    Click here

  21. DRAIN COOLANT (for Inverter)

    Click here

  22. REMOVE INLET NO. 1 AIR CLEANER


    1. B004EVL

      Remove the bolt and inlet No. 1 air cleaner.

  23. REMOVE AIR CLEANER CAP WITH NO. 2 AIR CLEANER HOSE

    Tech Tips

    Perform this procedure only when replacement of the air cleaner filter element sub-assembly or air cleaner case sub-assembly is necessary.

    Click here

  24. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the air cleaner filter element sub-assembly is necessary.


    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.

  25. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the air cleaner case sub-assembly is necessary.


    1. B004FP9C02
      *1 Air Cleaner Support

      Disconnect the wire harness clamp from the air cleaner case sub-assembly.

    2. Remove the 2 bolts and air cleaner case sub-assembly.

      Note

      Make sure the air cleaner support is attached to the vehicle body.

  26. REMOVE AIR CLEANER ASSEMBLY WITH NO. 2 AIR CLEANER HOSE


    1. B004FQLC01
      *1 Air Cleaner Support

      Disconnect the mass air flow meter sub-assembly connector.

    2. Disengage the 2 wire harness clamps from the air cleaner assembly with No. 2 air cleaner hose.

    3. Remove the 2 bolts.

    4. Loosen the hose clamp and remove the air cleaner assembly with No. 2 air cleaner hose from the air cleaner hose assembly.

      Note

      Make sure the air cleaner support is attached to the vehicle body.

  27. REMOVE AIR CLEANER HOSE ASSEMBLY

    Click here

  28. REMOVE HEATER WATER PUMP ASSEMBLY

    Click here

  29. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE


    1. B004G8J

      Slide the clip and disconnect the No. 2 fuel vapor feed hose from the No. 1 vacuum switching valve assembly.

  30. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. B004GNC

      Disengage the No. 1 fuel tube clamp from the wire harness clamp bracket.

    2. Disconnect the fuel tube sub-assembly from the fuel pump with seal sub-assembly.

      Click here

    3. Disconnect the fuel tube sub-assembly from the fuel delivery pipe.

      Click here

  31. REMOVE RADIATOR HOSE SUB-ASSEMBLY

    Click here

  32. DISCONNECT NO. 4 RADIATOR HOSE

    Click here

  33. DISCONNECT OUTLET HEATER WATER HOSE A

    Click here

  34. DISCONNECT INLET HEATER WATER HOSE A

    Click here

  35. REMOVE FRONT UPPER NO. 2 SUSPENSION MEMBER


    1. B004FQ5

      Remove the 6 bolts and 2 front upper No. 2 suspension members.

  36. DISCONNECT OUTLET NO. 2 OIL COOLER HOSE


    1. B004G01

      Slide the clip and disconnect the outlet No. 2 oil cooler hose from the oil cooler tube sub-assembly.

  37. DISCONNECT INLET NO. 2 OIL COOLER HOSE


    1. B004FTE

      Slide the clip and disconnect the inlet No. 2 oil cooler hose from the oil cooler tube sub-assembly.

  38. REMOVE OUTLET NO. 1 HV WATER PUMP PIPE


    1. B004GIOC01
      *1

      for LHD: No. 2 Inverter Cooling Hose

      for RHD: No. 5 Inverter Cooling Hose
      *2 Outlet No. 1 Hybrid Water Pump Hose
      *3 Outlet No. 1 HV Water Pump Pipe

      for LHD:


      1. Slide the clip and disconnect the No. 2 inverter cooling hose from the outlet No. 1 HV water pump pipe.

        Note

        Put pieces of cloth into the pipe and disconnected hose or cover the pipe and disconnected hose with plastic bags to prevent entry of foreign matter.

    2. for RHD:


      1. Slide the clip and disconnect the No. 5 inverter cooling hose from the outlet No. 1 HV water pump pipe.

        Note

        Put pieces of cloth into the pipe and disconnected hose or cover the pipe and disconnected hose with plastic bags to prevent entry of foreign matter.

    3. Slide the clip and disconnect the outlet No. 1 hybrid water pump hose from the inverter water pump assembly.

      Note

      Put pieces of cloth into the pipe and disconnected hose or cover the pipe and disconnected hose with plastic bags to prevent entry of foreign matter.

    4. Remove the 2 bolts and outlet No. 1 HV water pump pipe from the stiffening crankcase assembly.

  39. REMOVE INVERTER RESERVE TANK ASSEMBLY (for LHD)


    1. B004EBO

      Disconnect the 2 connectors.

    2. Disengage the 2 wire harness clamps.

    3. B004F4UC01
      *1 Inlet Hybrid Water Pump Hose
      *2 Outlet No. 2 Inverter Cooling Hose

      Disengage the clamp to disconnect the inlet hybrid water pump hose from the No. 1 inverter reserve tank bracket.

      Note

      Do not remove the clamp from the inlet hybrid water pump hose.

    4. Slide the clip and disconnect the inlet hybrid water pump hose from the inverter water pump assembly.

      Note

      Put pieces of cloth into the pipe and disconnected hose or cover the pipe and disconnected hose with plastic bags to prevent entry of foreign matter.

    5. Slide the clip and disconnect the outlet No. 2 inverter cooling hose from the inverter reserve tank assembly.

      Note

      Put pieces of cloth into the pipe and disconnected hose or cover the pipe and disconnected hose with plastic bags to prevent entry of foreign matter.

    6. Remove the 2 bolts and inverter reserve tank assembly from the No. 1 inverter reserve tank bracket.

  40. REMOVE INVERTER RESERVE TANK ASSEMBLY (for RHD)


    1. B004GVH

      Slide the clip and disconnect the inverter drain hose from the outlet HV radiator pipe.

      Note

      Put pieces of cloth into the pipe and disconnected hose or cover the pipe and disconnected hose with plastic bags to prevent entry of foreign matter.

    2. B004EPFC01
      *1 No. 3 Inverter Cooling Hose
      *2 Inlet Hybrid Water Pump Hose

      Disengage the 2 clamps to disconnect the No. 3 inverter cooling hose from the No. 1 inverter reserve tank bracket and HV water pump bracket sub-assembly.

      Note

      Do not remove the clamps from the No. 3 inverter cooling hose.

    3. Disengage the clamp to disconnect the inlet hybrid water pump hose from the No. 1 inverter reserve tank bracket.

      Note

      Do not remove the clamp from the inlet hybrid water pump hose.

    4. Slide the clip and disconnect the inlet hybrid water pump hose from the inverter water pump assembly.

      Note

      Put pieces of cloth into the pipe and disconnected hose or cover the pipe and disconnected hose with plastic bags to prevent entry of foreign matter.

    5. Remove the 2 bolts and inverter reserve tank assembly from the No. 1 inverter reserve tank bracket.

  41. REMOVE NO. 1 INVERTER RESERVE TANK BRACKET


    1. B004FLR

      for LHD:


      1. Disengage the clamp to disconnect the No. 3 inverter cooling hose from the No. 1 inverter reserve tank bracket.

        Note

        Do not remove the clamp from the No. 3 inverter cooling hose.

    2. B004F26

      Remove the bolt and disconnect the No. 3 engine wire from the No. 1 inverter reserve tank bracket.

    3. Disengage the 2 wire harness clamps from the No. 1 inverter reserve tank bracket.

    4. B004GW6

      Remove the 2 bolts.

    5. Disengage the claw and remove the No. 1 inverter reserve tank bracket.

  42. REMOVE ECM

    Click here

  43. REMOVE INVERTER MOTOR CABLE BRACKET ASSEMBLY

    Click here

  44. REMOVE INVERTER TERMINAL COVER

    Click here

  45. DISCONNECT MOTOR CABLE

    Click here

  46. DISCONNECT GENERATOR CABLE

    Click here

  47. DISCONNECT ENGINE WIRE

    Tech Tips

    After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way.


    1. Remove the No. 1 relay block cover from the engine room relay block and junction block assembly.

    2. B004GKAC01
      *a Push
      *b Pull up

      Disconnect the connector (A) from the No. 2 connector holder.

    3. Push in the lock lever of the connector (B) to unlock it and pull up the lock lever.

    4. Disconnect the connector (B) from the No. 2 connector holder.

    5. B004FBD

      Disengage the 3 claws and disconnect the No. 2 connector holder from the engine room relay block and junction block assembly.

  48. DISCONNECT AIR CONDITIONING HARNESS


    1. B004FZYC01
      *a Green-colored Lock

      Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the connector.

      CAUTION:

      Make sure to wear insulated gloves.

      Note

      Insulate the disconnected terminals and connector with insulating tape.

    2. Disengage the 2 wire harness clamps.

  49. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  50. REMOVE MANIFOLD STAY


    1. B004GRY

      Remove the 2 bolts and manifold stay.

  51. REMOVE ENGINE UNDER BRACE SUB-ASSEMBLY


    1. B004FNM

      Remove the 4 bolts and engine under brace sub-assembly.

  52. SEPARATE STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

    Click here

  53. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY LH


    1. B004FY3

      Remove the bolt and nut, and disconnect the lower part of the front shock absorber assembly LH from the front lower suspension arm assembly.

      Note

      When removing the bolt, keep the nut from rotating.

  54. SEPARATE FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  55. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

  56. SEPARATE FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  57. DISCONNECT WIRE HARNESS


    1. B004GDK

      Disconnect the 2 wire harness clamps and 3 wire harness connectors from the power steering link assembly.

      Tech Tips

      For the connector with lock lever, pull up the lock lever to disengage the lock.

  58. SEPARATE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  59. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. B004FQR

      Remove the 4 bolts and front lower suspension member protector from the front suspension crossmember sub-assembly.

  60. DISCONNECT SUCTION HOSE

    Click here

  61. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  62. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION


    1. B004F5U

      Remove the nut and disconnect the No. 2 earth wire.

    2. B004GH4C01
      B004FO9 Attachment Installation Position

      Place height adjustment attachments and plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine assembly with transmission.

      Note


      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transmission horizontally.

      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.

      • 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 or removed from an engine stand.

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

    3. B004E92

      Remove the 4 bolts and separate the rear engine mounting member.

    4. B004EJSC01
      B004FMB Bolt
      B004EIV Nut

      Remove the 4 bolts and separate the front No. 2 stabilizer bracket LH and front No. 2 stabilizer bracket RH.

    5. Remove the 6 bolts, 2 nuts, strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly.

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

      Note


      • Make sure that the engine assembly with transmission is clear of all wiring, hoses and the steering sliding with shaft yoke sub-assembly.

      • After removing the engine assembly with transmission, hang the steering sliding with shaft yoke sub-assembly with rope or equivalent.

  63. INSTALL ENGINE HANGER


    1. B004GPMC01
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      *a Stopper
      *b Rib
      *c Rear Edge

      Install the No. 1 engine hanger with the bolt.

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

      Note

      Make sure to install the No. 1 engine hanger with the stopper contacting the rib of the cylinder head sub-assembly as shown in the illustration.

      Tech Tips

      Item Part No.
      No. 1 Engine Hanger 12281-36060
      No. 2 Engine Hanger 12282-36061
      Bolt (No. 1 Engine Hanger) 91552-81040
      Bolt (No. 2 Engine Hanger) 90119-12285

    2. Install the No. 2 engine hanger with the bolt.

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

      Note

      Make sure to install the No. 2 engine hanger with the stopper contacting the rear edge of the cylinder head sub-assembly as shown in the illustration.

    3. Using an engine sling device and engine lift, secure the engine assembly.

      Note


      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.

      • 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.

  64. REMOVE ENGINE OIL LEVEL DIPSTICK


    1. Remove the engine oil level dipstick from the engine oil level dipstick guide.

  65. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. B004EZK

      Remove the bolt and engine oil level dipstick guide.

    2. Remove the O-ring from the engine oil level dipstick guide.

  66. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  67. REMOVE NO. 3 ENGINE WIRE


    1. B004FIC

      Disengage the clamp.

    2. Remove the bolt and No. 3 engine wire.

  68. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR


    1. B004E4B

      Remove the 2 nuts and No. 3 exhaust manifold heat insulator from the camshaft housing sub-assembly.

  69. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  70. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)

    Click here

  71. REMOVE MOTOR HEAT INSULATOR

    Click here

  72. DISCONNECT WIRE HARNESS

    Click here

  73. REMOVE OIL COOLER WITHOUT HOSE TUBE SUB-ASSEMBLY

    Click here

  74. SUPPORT HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here

  75. REMOVE HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here

  76. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly.

  77. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

    Click here

  78. REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  79. REMOVE V-RIBBED BELT

    Click here

  80. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  81. REMOVE THROTTLE BODY GASKET

    Click here

  82. REMOVE INJECTOR DRIVER

    Click here

  83. REMOVE PURGE VALVE (PURGE VSV)

    Click here

  84. REMOVE NO. 2 EGR PIPE

    Click here

  85. REMOVE INTAKE MANIFOLD

    Click here

  86. REMOVE OUTLET HEATER WATER HOSE A


    1. B004E52

      Remove the water hose set from the outlet heater water hose A.

    2. B004EG6

      Slide the clip and disconnect the outlet heater water hose A from the No. 2 water by-pass pipe.

  87. REMOVE INLET HEATER WATER HOSE B


    1. B004ECI

      Slide the clip and disconnect the inlet heater water hose B from the No. 3 water by-pass pipe.

  88. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. B004FJXC01
      *a LH Side
      *b RH Side

      Remove the 2 nuts and front suspension crossmember sub-assembly from the front engine mounting insulators.

  89. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. B004E3IC01
      *a LH Side
      *b RH Side

      Remove the 2 bolts and 2 front engine mounting insulators from the front No. 1 engine mounting bracket LH and front No. 1 engine mounting bracket RH.

  90. REMOVE REAR ENGINE MOUNTING MEMBER

    Tech Tips

    Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.


    1. B004GCH

      Remove the 4 nuts and rear engine mounting member from the rear No. 1 engine mounting insulator.

  91. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.


    1. B004FWI

      Remove the 4 bolts and rear No. 1 engine mounting insulator from the hybrid vehicle transmission assembly.

  92. INSTALL ENGINE ASSEMBLY TO ENGINE STAND


    1. Install the engine assembly to an engine stand.

      Note


      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.

      • 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 or removed from an engine stand.

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

  93. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. B004F29

      Using a precision straightedge and feeler gauge, check the surface which contacts the cylinder head sub-assembly for warpage.

      Maximum Warpage
      0.7 mm (0.0276 in.)

      If the warpage is more than the maximum, replace the exhaust manifold converter sub-assembly (TWC: Front Catalyst).