ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

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.

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 auxiliary battery terminal notice before proceeding with work Click here.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. REMOVE REAR NO. 2 FLOOR BOARD

    Click here

  4. REMOVE REAR DECK FLOOR BOX

    Click here

  5. REMOVE REAR NO. 3 FLOOR BOARD

    Click here

  6. REMOVE DECK FLOOR BOX RH

    Click here

  7. REMOVE REAR FLOOR BOARD UPPER NO. 3 PLATE

    Click here

  8. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  9. REMOVE SERVICE PLUG GRIP

    Click here

  10. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  11. REMOVE FRONT WHEEL

  12. REMOVE REAR ENGINE UNDER COVER LH


    1. Remove the 5 clips and rear engine under cover LH.

  13. REMOVE REAR ENGINE UNDER COVER RH


    1. Remove the 5 clips and rear engine under cover RH.

  14. REMOVE FRONT LOWER BUMPER ABSORBER


    1. Remove the 8 bolts, 4 screws and front lower bumper absorber.

  15. REMOVE NO. 1 ENGINE UNDER COVER


    1. Remove the 2 bolts, 13 clips and No. 1 engine under cover.

  16. DRAIN ENGINE OIL

    Click here

  17. DRAIN COOLANT (for Engine)

    Click here

  18. DRAIN COOLANT (for Inverter)

    Click here

  19. DRAIN HYBRID TRANSAXLE FLUID

    Click here

  20. REMOVE NO. 2 CYLINDER HEAD COVER


    1. B001LKQE02

      Disengage the 3 clips and remove the No. 2 cylinder head cover.

      Note


      • Disengage the clips in the order shown in the illustration.

      • When disengaging clip 3, hold the end of the No. 2 cylinder head cover behind clip 3 and lift the No. 2 cylinder head cover straight up.

      • Attempting to disengage both front and rear clips at the same time may cause the No. 2 cylinder head cover to break.

      • Pull the No. 2 cylinder head cover straight up to remove. Attempting to pull the No. 2 cylinder head cover forward or attempting to pull it up by holding the left and right ends may cause the No. 2 cylinder head cover to break.

  21. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. B001LCX

      Disconnect the air flow meter connector.

    2. Disconnect the water by-pass hose from the air cleaner cap sub-assembly.

    3. Disconnect the 2 clamps and remove the air cleaner cap sub-assembly.

    4. Loosen the hose clamp and disconnect the air cleaner hose assembly.

    5. Remove the air cleaner filter element sub-assembly.

  22. REMOVE WATER HOSE HOSE CLAMP


    1. B001MWA

      Disconnect the water by-pass hose from the water hose hose clamp.

    2. Remove the 2 clips and water hose hose clamp.

  23. REMOVE INLET AIR CLEANER


    1. B001M2V

      Disconnect the wire harness clamp from the inlet air cleaner.

    2. Remove the 2 bolts and inlet air cleaner.

  24. REMOVE AIR CLEANER CASE


    1. B001KVX

      Disconnect the No. 4 water by-pass hose from the air cleaner case.

    2. Disconnect the wire harness clamp from the air cleaner case.

    3. Remove the 2 bolts and air cleaner case.

  25. REMOVE AIR CLEANER HOSE ASSEMBLY

    Click here

  26. REMOVE RADIATOR SUPPORT OPENING COVER

    Click here

  27. REMOVE INVERTER COVER ASSEMBLY LH (w/ Cover)

    Click here

  28. REMOVE NO. 1 INVERTER BRACKET

    Click here

  29. DISCONNECT ENGINE ROOM MAIN WIRE

    Click here

  30. REMOVE INVERTER COVER

    Click here

  31. CHECK TERMINAL VOLTAGE

    Click here

  32. DISCONNECT FRAME WIRE

    Click here

  33. DISCONNECT GENERATOR CABLE

    Click here

  34. DISCONNECT MOTOR CABLE

    Click here

  35. DISCONNECT NO. 2 ENGINE WIRE

    Click here

  36. INSTALL INVERTER COVER

    Click here

  37. DISCONNECT NO. 2 ENGINE ROOM WIRE

    Click here

  38. DISCONNECT WATER HOSE

    Click here

  39. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

  40. SEPARATE INVERTER RESERVE TANK ASSEMBLY


    1. B001M9Z

      Remove the 2 bolts and separate the inverter reserve tank assembly.

  41. REMOVE INVERTER TRAY BRACKET


    1. B001KY5

      Disconnect the 2 clamps from the inverter tray bracket.

    2. Remove the 5 bolts and inverter tray bracket.

  42. DISCONNECT NO. 1 RADIATOR HOSE


    1. B001ML2

      Slide the clip and disconnect the No. 1 radiator hose from the radiator pipe.

  43. DISCONNECT NO. 2 RADIATOR HOSE


    1. B001LV0

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

  44. DISCONNECT NO. 4 WATER BY-PASS HOSE


    1. B001NEX

      Slide the clip and disconnect the No. 4 water by-pass hose from the radiator pipe.

  45. DISCONNECT NO. 3 INVERTER COOLING HOSE


    1. B001LQAE02
      Text in Illustration
      *1 No. 3 Inverter Cooling Hose
      *2 No. 5 Inverter Cooling Hose

      Slide the clip and disconnect the No. 3 inverter cooling hose from the hybrid transaxle assembly.

  46. DISCONNECT NO. 5 INVERTER COOLING HOSE


    1. Slide the clip and disconnect the No. 5 inverter cooling hose from the hybrid transaxle assembly.

  47. DISCONNECT OUTLET HEATER WATER HOSE


    1. B001M8O

      Slide the clip and disconnect the outlet heater water hose.

  48. DISCONNECT INLET HEATER WATER HOSE


    1. B001N59

      Slide the clip and disconnect the inlet heater water hose.

  49. DISCONNECT HEATER HOSE


    1. B001NFL

      Slide the clip and disconnect the heater hose.

  50. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. B001LR8

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

  51. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. B001KL8

      Release the claw and remove the No. 1 fuel pipe clamp.

    2. B001LP6

      Pinch the retainer as illustrated, then pull the fuel tube connector out of the fuel pipe.

      Note


      • Remove any dirt and foreign matter from the fuel tube connector before performing this work.

      • Do not allow any scratches or foreign matter to get on the parts when disconnecting, as the fuel tube connector has the O-rings that seal the fuel pipe.

      • Perform this work by hand. Do not use any tools.

      • Do not forcibly bend, kink or twist the nylon tube.

      • Protect the disconnected parts by covering them with plastic bags after disconnecting the fuel tube.

      • If the fuel tube connector and fuel pipe are stuck, push and pull to release them.

  52. SEPARATE ELECTRIC INVERTER COMPRESSOR

    Click here

  53. DISCONNECT WIRE HARNESS


    1. B001K8K

      Disconnect the 2 clamps.

    2. Pull up the lever and disconnect the ECM connector.

    3. B001MWZ

      Disconnect the 2 connectors, 2 clamps and engine wire from the engine room junction block.

    4. B001MY5

      Disconnect the 2 clamps and engine wire.

    5. B001L3S

      Remove the bolt and disconnect the earth wire.

    6. B001LFJ

      Disconnect the 2 clamps and engine wire.

  54. SECURE STEERING WHEEL

    Click here

  55. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  56. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  58. REMOVE FRONT NO. 3 ENGINE UNDER COVER

    Click here

  59. REMOVE FRONT CENTER FLOOR BRACE

    Click here

  60. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  61. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  62. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  63. SEPARATE FRONT SPEED SENSOR LH

    Click here

  64. SEPARATE FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  65. SEPARATE TIE ROD END SUB-ASSEMBLY LH

    Click here

  66. SEPARATE TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  67. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  68. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  69. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

    Click here

  70. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  71. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  72. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  73. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  74. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  75. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  76. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING RH

    Tech Tips

    Perform the same procedure as for the LH side.

  77. REMOVE FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT

    Click here

  78. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  79. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Click here

  80. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  81. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  82. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  83. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine lifter.

      Note


      • Place height adjustment attachments and plate lift attachments under the engine assembly with transaxle.

      • Do not position the height adjustment attachments or plate lift attachments under the front crossmember sub-assembly.

    2. B001KVD

      Remove the 4 bolts to separate the front crossmember sub-assembly from the vehicle body.

    3. B001N8A

      Remove the bolt and 2 nuts, and separate the engine mounting insulator sub-assembly RH.

    4. B001LWB

      Remove the bolt and nut, and separate the engine mounting insulator LH.

    5. Carefully remove the engine assembly with transaxle from the vehicle.

      Note

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

    6. B001LOE

      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 }
      Part Name Part No.
      No. 1 engine hanger 12281-37021
      No. 2 engine hanger 12282-37011
      Bolt 91552-81050

    7. Attach the sling device to the engine hangers and chain block.

  84. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY


    1. B001LYQ

      Remove the bolt, nut and front crossmember sub-assembly.

      Tech Tips

      When removing the bolt, keep the nut from rotating.

  85. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. B001L81

      Remove the 2 bolts and front engine mounting insulator.

  86. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B001L2K

      Remove the bolt and rear engine mounting insulator from the rear engine mounting bracket.

  87. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B001MVE

      Remove the 4 bolts and engine mounting insulator LH.

  88. SEPARATE RADIATOR RESERVOIR TANK ASSEMBLY

    Tech Tips

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


    1. B001K9TE02
      Text in Illustration
      *A w/ Cover
      *B w/o Cover

      Remove the 2 bolts and separate the radiator reservoir tank assembly.

  89. 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. B001MDN

      Remove the 2 bolts and 2 cooler brackets.

    2. Remove the 3 bolts and engine mounting insulator sub-assembly RH.

  90. REMOVE RADIATOR PIPE


    1. B001L5T

      Remove the 2 bolts.

    2. Slide the clip and disconnect the No. 3 radiator hose and remove the radiator pipe from the cylinder head.

  91. REMOVE STARTER HOLE INSULATOR

    Click here

  92. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  93. REMOVE ENGINE WIRE

  94. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. Remove the hybrid vehicle transaxle assembly Click here.

      Note

      Be careful not to apply excess force to the transmission input damper assembly when removing or installing the hybrid vehicle transaxle assembly. If excess force is applied, the transmission input damper assembly may be damaged, or its splines may become misaligned.

  95. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY


    1. Gently place the engine assembly onto wooden blocks or equivalent.

      Note

      This step should be done while hanging the engine assembly using the engine hangers and a chain block.

    2. Remove the transmission input damper assembly Click here.

  96. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. Gently place the engine assembly onto wooden blocks or equivalent.

      Note

      This step should be done while hanging the engine assembly using the engine hangers and a chain block.

    2. Remove the flywheel sub-assembly Click here.