ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transmission is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

PROCEDURE


  1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  3. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  4. REMOVE LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (w/ Spare Tire)

    Click here

  5. REMOVE DECK BOARD ASSEMBLY (w/o Spare Tire)

    Click here

  6. REMOVE DECK TRIM SIDE BOARD LH (w/o Spare Tire)

    Click here

  7. REMOVE BATTERY SERVICE HOLE COVER LH

    Click here

  8. PRECAUTION

    Note

    After turning the power switch off, waiting time may be required before disconnecting the cable from the auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery terminal notice before proceeding with work Click here.

  9. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    CAUTION:

    Wait at least 90 seconds after disconnecting the cable from the auxiliary negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

    Note

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

  10. REMOVE SERVICE PLUG GRIP

    Click here

  11. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A000XDYE03

      While using both hands, lift the rear side of the V-bank cover sub-assembly upwards to detach the 4 clips labeled B. Slide the V-bank cover sub-assembly towards the front of the vehicle to detach the 2 clips labeled A, and remove the V-bank cover sub-assembly.

      Note

      The V-bank cover sub-assembly may be damaged if its front and rear are lifted at the same time.

  12. REMOVE AIR CLEANER INLET COVER SUB-ASSEMBLY


    1. A000U9HE04

      Remove the 5 clips labeled A.

    2. Lift up the air cleaner inlet cover sub-assembly to detach the 4 clips labeled B, and remove the air cleaner inlet cover sub-assembly.

  13. REMOVE NO. 1 AIR CLEANER INLET


    1. A000T9M

      Remove the 2 bolts.

    2. A000XJVE03
      *1 Protrusion

      Hold the No. 1 air cleaner inlet by the protrusions labeled A and B, and detach the connections.

    3. Rotate the No. 1 air cleaner inlet as shown in the illustration to detach the protrusion labeled C.

    4. Hold the No. 1 air cleaner inlet by the protrusions labeled D and E, and detach the connections.

    5. Rotate the No. 1 air cleaner inlet as shown in the illustration to detach the protrusion labeled F.

  14. REMOVE ENGINE ROOM SIDE COVER RH

    Click here

  15. REMOVE ENGINE ROOM SIDE COVER LH

    Click here

  16. REMOVE COWL TOP VENTILATOR LOUVER RH (for LHD)

    Click here

  17. REMOVE COWL TOP VENTILATOR LOUVER LH (for RHD)

    Tech Tips

    Use the same procedures described for LHD vehicles.

  18. REMOVE MOTOR CABLE COVER RH (for LHD)


    1. A000V15

      Remove the 2 clips and motor cable cover RH.

  19. REMOVE MOTOR CABLE COVER LH (for RHD)


    1. A000X59

      Remove the 2 clips and motor cable cover LH.

  20. REMOVE INVERTER COVER ASSEMBLY RH (for LHD)


    1. A000T8O

      Detach the 2 clips and remove the inverter cover assembly RH.

  21. REMOVE INVERTER COVER ASSEMBLY LH (for RHD)


    1. A000YBF

      Detach the 2 clips and remove the inverter cover assembly LH.

  22. REMOVE CONNECTOR COVER ASSEMBLY (for LHD)

    Click here

  23. CHECK TERMINAL VOLTAGE (for LHD)

    Click here

  24. INSTALL CONNECTOR COVER ASSEMBLY (for LHD)

    Click here

  25. REMOVE CONNECTOR COVER ASSEMBLY (for RHD)

    Click here

  26. CHECK TERMINAL VOLTAGE (for RHD)

    Click here

  27. INSTALL CONNECTOR COVER ASSEMBLY (for RHD)

    Click here

  28. REMOVE FRONT CENTER FLOOR COVER (w/ Cover)


    1. A000ULR

      Remove the 3 screws, 2 bolts, clip and front center floor cover.

  29. REMOVE NO. 2 ENGINE UNDER COVER


    1. A000TXJ

      Remove the 4 screws, 2 clips and No. 2 engine under cover.

  30. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

    Click here

  31. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

    Click here

  32. REMOVE NO. 1 ENGINE UNDER COVER

    Click here

  33. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. A000VIS

      Remove the 9 bolts and front lower suspension member protector.

  34. DRAIN ENGINE OIL

    Click here

  35. DRAIN ENGINE COOLANT

    Click here

  36. DRAIN COOLANT (for Inverter)

    Click here

  37. DRAIN FRONT DIFFERENTIAL OIL

    Click here

  38. DISCONNECT INLET OIL COOLER HOSE

    Click here

  39. DISCONNECT OUTLET OIL COOLER HOSE

    Click here

  40. REMOVE FRONT BUMPER COVER

    Click here

  41. DISCONNECT FRONT FENDER LINER LH (w/ Active Stabilizer System)

    Click here

  42. REMOVE NO. 3 COOL AIR INTAKE DUCT SUB-ASSEMBLY (w/ Active Stabilizer System)

    Click here

  43. REMOVE INLET ENGINE ROOM ECM DUCT (w/ Active Stabilizer System)

    Click here

  44. DISCONNECT FRONT ACTIVE STABILIZER CONTROL ACTUATOR CONNECTOR (w/ Active Stabilizer System)

    Click here

  45. REMOVE REAR FRAME SIDE RAIL


    1. A000UH5

      Remove the 6 bolts, 4 nuts and 2 rear frame side rails.

  46. REMOVE INTAKE AIR CONNECTOR PIPE

    Click here

  47. REMOVE AIR CLEANER ASSEMBLY LH

    Click here

  48. REMOVE AIR CLEANER ASSEMBLY RH

    Click here

  49. REMOVE RADIATOR RESERVOIR ASSEMBLY

    Click here

  50. REMOVE OUTLET ENGINE ROOM ECM DUCT


    1. A000TOD

      Remove the outlet engine room ECM duct.

  51. REMOVE NO. 1 RADIATOR HOSE

  52. REMOVE NO. 2 RADIATOR HOSE

  53. REMOVE RESONATOR BRACKET SUB-ASSEMBLY

    Click here

  54. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  55. DISCONNECT NO. 1 FUEL HOSE

    Click here

  56. DISCONNECT NO. 3 FUEL HOSE

    Click here

  57. REMOVE INVERTER TERMINAL COVER (for LHD)

    Click here

  58. DISCONNECT MOTOR CABLE (for LHD)

    Click here

  59. DISCONNECT GENERATOR CABLE (for LHD)

    Click here

  60. REMOVE INVERTER TERMINAL COVER (for RHD)

    Click here

  61. DISCONNECT MOTOR CABLE (for RHD)

    Click here

  62. DISCONNECT GENERATOR CABLE (for RHD)

    Click here

  63. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. A000TPW

      Remove the bolt. Then disconnect the discharge hose sub-assembly.

    2. Remove the O-ring from the discharge hose sub-assembly.

      Note

      Seal the openings of the disconnected parts and motor compressor using vinyl tape and/or plastic bags to prevent moisture and foreign matter from entering them.

  64. DISCONNECT SUCTION HOSE SUB-ASSEMBLY


    1. A000VLG

      Remove the bolt. Then disconnect the suction hose sub-assembly.

    2. Remove the O-ring from the suction hose sub-assembly.

      Note

      Seal the openings of the disconnected parts and motor compressor using vinyl tape and/or plastic bags to prevent moisture and foreign matter from entering them.

  65. REMOVE WATER PUMP ASSEMBLY WITH MOTOR AND BRACKET

    Click here

  66. DISCONNECT HOSES AND CONNECTORS


    1. A000TIH

      Remove the 3 bolts and engine room ECU cover.

    2. A000XTDE03

      Disconnect the 4 hybrid vehicle control ECU connectors and 2 wiring harness support connectors.

    3. Detach the 2 wiring harness support clips, and then detach the clip of connector A from the ECM box.

      Tech Tips

      It is not necessary to disconnect the connection at A in the illustration.

    4. A000Z7F

      Lift up the wiring harness support and disconnect the 4 ECM connectors.

    5. A000VJ3

      Detach the clamp and disconnect the 3 connectors from the front controller.

    6. A000TPM

      Remove the nut and ground wire.

    7. Disconnect the 2 oil pump motor controller connectors.

      Tech Tips

      Refer to the following procedures to disconnect the oil pump driver connector Click here.

    8. A000XRQ

      Disconnect the heater water pump connector.

    9. Detach the 2 clamps. Then remove the nut and inverter cooling pipe bracket.

    10. Remove the 2 nuts, heater water pump and bracket.

    11. A000UAJ

      Disconnect the 2 connectors and detach the 5 clamps.

    12. for LHD:


      1. A000U6G

        Disconnect the heater wire connector.

      2. A000V98

        Disconnect the No. 5 inverter cooling hose and purge line hose.

      3. A000YR7

        Disconnect the 2 heater hoses.

    13. for RHD:


      1. A000X3R

        Disconnect the heater wire connector.

      2. A000UCE

        Disconnect the outlet No. 2 inverter cooling hose and purge line hose.

      3. A000Z2I

        Disconnect the 2 heater hoses and No. 6 inverter cooling hose.

  67. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY

    Click here

  68. REMOVE NO. 1 AIR DUCT SUB-ASSEMBLY (for RHD)


    1. A000TQF

      Detach the 2 claws, and remove the bolt and No. 1 air duct sub-assembly.

      Note

      Be careful not to damage the No. 1 air duct sub-assembly as its connection to the vehicle is very tight.

  69. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY (for LHD)


    1. A000ZG2

      Detach the 2 claws, and remove the bolt and No. 2 air duct sub-assembly.

      Note

      Be careful not to damage the No. 2 air duct subassembly as its connection to the vehicle is very tight.

  70. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  71. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  72. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  73. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click here

  74. DISCONNECT TRANSMISSION CONTROL SHAFT LEVER


    1. A000TIL

      Remove the nut and spring washer, and then disconnect the transmission control shaft lever from the position sensor.

  75. DISCONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY RH


    1. A000WGA

      Remove the bolt. Then disconnect the front lower shock absorber bracket sub-assembly RH.

  76. DISCONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY LH


    1. A000ZV4

      Remove the bolt. Then disconnect the front lower shock absorber bracket sub-assembly LH.

  77. REMOVE ENGINE AND TRANSMISSION


    1. A000UR8

      Place a mark (with spray, etc.) over the rear right vehicle side attachment area of the front frame, which is indicated in the illustration.

    2. Place a mark (with spray, etc.) over the rear left vehicle side attachment area of the front frame.

    3. Set an engine lifter underneath the engine.

      Note


      • Place wooden blocks or plate lift attachments so that the engine is level.

      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

      • Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.

    4. A000XNA

      Remove the 4 rear engine mounting member's bolts.

    5. A000UIJ

      Remove the 4 bolts shown in the illustration.

    6. Operate the engine lifter, then slowly remove the engine from the vehicle.

      Note


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

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

  78. INSTALL ENGINE HANGER


    1. A000Z0J

      Install the 2 engine hangers with the 2 bolts as shown in the illustration.

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

      Tech Tips

      Engine hanger 12281-38150
      Bolt 90119-14120
    2. A000WTKE01
      *1 50° or less
      *2 Engine Hanger
      *3 ENGINE

      Attach an engine sling device and hang the engine with a chain block.

      Note

      When hanging the engine, make sure to hang the engine with the sling device's hanging angle at 50° or less. If not, the engine or engine hangers may be damaged.

  79. REMOVE FRONT FRAME ASSEMBLY


    1. A000YI4

      Disconnect the heater wire connector and detach the 2 clips.

    2. A000YXAE01
      *1 for RH:
      *2 for LH:

      Remove the 4 nuts and front frame assembly.

  80. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A000Y0GE02
      *1 O-Ring
      *2 Pull

      Remove the engine oil level dipstick.

    2. Remove the bolt and engine oil level dipstick guide.

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

  81. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  82. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  83. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A000UVPE01

      Remove the 2 nuts, 2 spacers and 2 front engine mounting insulators.

  84. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. A000TCT

      Remove the 5 bolts and front No. 1 engine mounting bracket RH.

  85. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. A000UU5

      Remove the 5 bolts and front No. 1 engine mounting bracket LH.

  86. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  87. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  88. REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET RH


    1. A000XKI

      Remove the 2 bolts and front No. 2 engine mounting bracket RH.

  89. REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET LH


    1. A000Z40

      Remove the 2 bolts and front No. 2 engine mounting bracket LH.

  90. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  91. REMOVE REAR ENGINE MOUNTING MEMBER

    Tech Tips

    Only perform this procedure when replacement of the rear engine mounting member is necessary.

    A000X31

    1. Remove the 5 nuts, No. 3 mounting insulator and rear engine mounting member.

  92. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    Only perform this procedure when replacement of the rear No. 1 engine mounting insulator is necessary.

    A000Z5V

    1. Remove the 4 bolts and 2 rear No. 1 engine mounting insulators.

  93. REMOVE REAR NO. 2 ENGINE MOUNTING INSULATOR

    Tech Tips

    Only perform this procedure when replacement of the rear No. 2 engine mounting insulator is necessary.

    A000XGY

    1. Remove the 2 bolts and rear No. 2 engine mounting insulator.

  94. REMOVE OIL COOLER TUBE SUB-ASSEMBLY

    Click here

  95. REMOVE OUTLET NO. 1 HYBRID WATER PUMP PIPE (for LHD)


    1. A000WDA

      Remove the 2 bolts and outlet No. 1 hybrid water pump pipe.

  96. REMOVE STARTER HOLE INSULATOR

    Click here

  97. REMOVE HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here

  98. REMOVE INPUT TRANSMISSION DAMPER COVER ASSEMBLY


    1. A000TKX

      Remove the 9 bolts and input transmission damper cover assembly.

  99. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A000UDWE01

      Using SST, hold the crankshaft.

      SST
      09213-54015   ( 90119-08216 )
      09330-00021
    2. A000YFJ

      Remove the 10 bolts, crankshaft angle sensor plate and flywheel sub-assembly.

  100. INSTALL ENGINE TO ENGINE STAND


    1. Install the engine onto an engine stand with the bolts.

      Note


      • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

    2. Remove the 2 bolts and 2 engine hangers.