ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

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.

PROCEDURE


  1. PRECAUTION

    CAUTION:

    Be sure to read Precaution thoroughly before servicing 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


    1. A000QWY

      Remove the 4 clips and engine room side cover.

  3. REMOVE COOL AIR INTAKE DUCT SEAL


    1. A000T5P

      Remove the 7 clips and cool air intake duct seal.

  4. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A000SOVE02
      Text in Illustration
      *a When detaching the clip on the rear side of the cover
      B002BQR Areas to be held when lifting the No. 1 engine cover sub-assembly

      Place both hands on either side of the No. 1 engine cover sub-assembly as shown in the illustration and detach the left and right side clips (1 and 2) near the front of the cover. Then, lift up the cover to detach the clip (3) on the rear side and remove the cover.

      Note


      • If the left and right sides and front and back sides of the cover are lifted up at the same time, the cover may be damaged.

      • If the procedures are not followed exactly, the clip on the rear side of the cover may be damaged.

      • If you attempt to remove the cover with only one of the front clips detached, the cover may be damaged.

  5. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  6. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  7. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  8. SECURE STEERING WHEEL

    Click here

  9. REMOVE LUGGAGE COMPARTMENT FLOOR MAT

    Click here

  10. REMOVE LUGGAGE COMPARTMENT TRIM COVER LH

    Click here

  11. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL

    Click here

  12. REMOVE NO. 1 SEAT ARMREST CAP

    Click here

  13. REMOVE LOWER HYBRID VEHICLE BATTERY COVER PANEL

    Click here

  14. REMOVE SERVICE PLUG GRIP

    Click here

  15. REMOVE INVERTER COVER

    Click here

  16. REMOVE CONNECTOR COVER ASSEMBLY

    Click here

  17. CHECK TERMINAL VOLTAGE

    Click here

  18. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

    Click here

  19. REMOVE ENGINE UNDER COVER


    1. A000PKL

      Remove the 13 screws, 3 clips and engine under cover.

  20. REMOVE REAR ENGINE UNDER COVER LH


    1. A000QI4

      Remove the screw and rear engine under cover LH.

  21. REMOVE REAR ENGINE UNDER COVER RH

    Tech Tips

    Use the same procedure described for the LH side.

  22. REMOVE FRONT SUSPENSION MEMBER BRACE


    1. A000MXP

      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.

  23. REMOVE NO. 2 ENGINE UNDER COVER


    1. A000OZV

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

  24. DRAIN ENGINE OIL

    Click here

  25. DRAIN ENGINE COOLANT (for Engine)

    Click here

  26. DRAIN COOLANT (for Inverter)

    Click here

  27. REMOVE NO. 1 AIR CLEANER INLET


    1. A000RTE

      Remove the bolt and No. 1 air cleaner inlet.

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

    Click here

  29. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

  30. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A000R7SE02
      Text in Illustration
      *a 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.

  31. REMOVE AIR CLEANER HOSE ASSEMBLY

    Click here

  32. REMOVE INVERTER MOTOR CABLE BRACKET ASSEMBLY

    Click here

  33. REMOVE INVERTER TERMINAL COVER

    Click here

  34. REMOVE ENGINE MOTOR CABLE CLAMP BRACKET (for LHD)


    1. A000PNV

      Detach the generator cable and motor cable from the engine motor cable clamp bracket.

    2. Remove the bolt and engine motor cable clamp bracket.

  35. DISCONNECT GENERATOR CABLE

    Click here

  36. DISCONNECT MOTOR CABLE

    Click here

  37. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE


    1. A000P5I

      Slide the clip and disconnect the No. 2 fuel vapor feed hose from the purge VSV.

  38. REMOVE FUEL TUBE SUB-ASSEMBLY


    1. A000QGB

      Disconnect 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.

  39. REMOVE RADIATOR HOSE SUB-ASSEMBLY

    Click here

  40. DISCONNECT NO. 2 RADIATOR HOSE SUB-ASSEMBLY

    Click here

  41. DISCONNECT HEATER WATER HOSE OUTLET A

    Click here

  42. DISCONNECT HEATER WATER HOSE INLET A

    Click here

  43. REMOVE HEATER WATER PUMP ASSEMBLY

    Click here

  44. DISCONNECT NO. 2 OIL COOLER OUTLET HOSE


    1. A000QJ8

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

  45. DISCONNECT NO. 2 OIL COOLER INLET HOSE


    1. A000MUK

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

  46. DISCONNECT SUCTION HOSE

    Click here

  47. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  48. DISCONNECT AIR CONDITIONING HARNESS


    1. A000SHQE01
      Text in Illustration
      *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 removed terminals and connector with insulating tape.

    2. Detach the 2 wire harness clamps.

  49. REMOVE ECM

    Click here

  50. 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 engine room relay block cover from the engine room relay block and junction block assembly.

    2. A000RYUE02
      Text in Illustration
      *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. A000SBU

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

    6. A000NE4

      for LHD:


      1. Disconnect the 2 wire harness connectors.

      2. Detach the wire harness clamp.

  51. REMOVE HV WATER PUMP BRACKET SUB-ASSEMBLY

    Click here

  52. REMOVE NO. 1 HV WATER PUMP OUTLET PIPE


    1. A000RKRE02
      Text in Illustration
      *1

      for LHD: No. 2 Inverter Cooling Hose

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

      for LHD:


      1. Slide the clip and disconnect the No. 2 inverter cooling hose from the No. 1 HV water pump outlet 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 No. 1 HV water pump outlet 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. Remove the 2 bolts and No. 1 HV water pump outlet pipe from the stiffening crankcase assembly.

  53. REMOVE INVERTER RESERVE TANK ASSEMBLY (for LHD)


    1. A000NVEE02
      Text in Illustration
      *1 Hybrid Water Pump Inlet Hose
      *2 No. 1 Inverter Cooling Hose
      *3 No. 3 Inverter Cooling Hose

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

      Note

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

    2. Detach 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.

    3. Detach the wire harness clamp from the inverter reserve tank assembly.

    4. Slide the clip and disconnect the No. 1 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.

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

  54. REMOVE INVERTER RESERVE TANK ASSEMBLY (for RHD)


    1. A000SYO

      Slide the clip and disconnect the inverter drain hose from the HV radiator outlet 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. A000T1VE02
      Text in Illustration
      *1 No. 3 Inverter Cooling Hose
      *2 Hybrid Water Pump Inlet Hose

      Detach the 2 clamps to disconnect the No. 3 inverter cooling hose from the No. 1 inverter reserve tank bracket.

      Note

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

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

      Note

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

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

  55. REMOVE NO. 1 INVERTER RESERVE TANK BRACKET


    1. A000N3M

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

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

    3. B002BMV

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

  56. REMOVE NO. 1 REAR FLOOR BOARD SUB-ASSEMBLY

    Click here

  57. REMOVE NO. 2 REAR FLOOR BOARD SUB-ASSEMBLY

    Click here

  58. REMOVE FRONT CENTER FLOOR BRACE

    Click here

  59. DISCONNECT HEATED OXYGEN SENSOR


    1. Disconnect the heated oxygen sensor connector.

    2. Disconnect the clamp.

  60. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  61. REMOVE MANIFOLD STAY


    1. A000RDS

      Remove the 2 bolts and manifold stay.

  62. REMOVE FRONT CENTER FLOOR BRACE SUB-ASSEMBLY


    1. A000R84

      Remove the 4 bolts and front center floor brace sub-assembly.

  63. REMOVE NO. 1 FUEL TANK PROTECTOR

    Click here

  64. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

    Click here

  65. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  66. DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

    Click here

  67. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY LH


    1. A000QV7

      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.

  68. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  69. DISCONNECT FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

  70. DISCONNECT FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  71. DISCONNECT POWER STEERING LINK WIRE HARNESS


    1. A000P8RE02

      Disconnect the 2 wire harness clamps from the bracket.

    2. Disconnect the 2 connectors (A and B) from the power steering link assembly.

    3. Release the lock of connector (C) and disconnect the connector from the power steering link assembly.

      Tech Tips

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

  72. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  73. REMOVE FRONT NO. 2 UPPER SUSPENSION MEMBER


    1. A000RH9

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

  74. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. A000PZX

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

  75. REMOVE ENGINE ASSEMBLY WITH TRANSMISSION


    1. A000MW9

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

    2. A000QXPE02
      Text in Illustration
      *a 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. A000NX0

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

    4. A000P9R

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

      Text in Illustration
      B002B6O Bolt
      B002BBR Nut

    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 to 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.

  76. INSTALL ENGINE HANGER


    1. A000RJOE02
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      *a Claw
      *b Groove

      Install the No. 1 engine hanger with the bolt.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      HINT
      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. Align the claw of the No. 2 engine hanger with the groove of the cylinder head sub-assembly and install the No. 2 engine hanger with the bolt.

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

      Note

      When installing the No. 2 engine hanger, make sure the No. 2 engine hanger is securely installed to the cylinder head sub-assembly with the bolt.

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

      Note


      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hanger from deforming or becoming damaged.

      • 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.

  77. REMOVE ENGINE OIL LEVEL DIPSTICK


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

  78. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A000SVY

      Remove the bolt and engine oil level dipstick guide.

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

  79. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  80. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR


    1. A000QI1

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

  81. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  82. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  83. REMOVE MOTOR HEAT INSULATOR

    Click here

  84. DISCONNECT WIRE HARNESS

    Click here

  85. REMOVE OIL COOLER WITHOUT HOSE TUBE SUB-ASSEMBLY

    Click here

  86. SUPPORT HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here

  87. REMOVE HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here

  88. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly.

  89. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

    Click here

  90. REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  91. REMOVE FAN AND GENERATOR V BELT

    Click here

  92. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  93. REMOVE INJECTOR DRIVER

    Click here

  94. REMOVE PURGE VSV

    Click here

  95. REMOVE NO. 2 EGR PIPE (w/ EGR System)

    Click here

  96. REMOVE INTAKE MANIFOLD

    Click here

  97. REMOVE HEATER WATER HOSE OUTLET A


    1. A000R0B

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

    2. A000OX1

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

  98. REMOVE HEATER WATER HOSE INLET B


    1. A000Q1W

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

  99. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A000MSBE01
      Text in Illustration
      *a LH Side
      *b RH Side

      Remove the 2 bolts and front suspension crossmember sub-assembly from the engine assembly.

  100. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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

    A000PL1E01

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

      Text in Illustration
      *a LH Side
      *b RH Side

  101. REMOVE REAR ENGINE MOUNTING MEMBER

    Tech Tips

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

    A000MX0

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

  102. 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. B002BQ7

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

  103. INSTALL ENGINE ASSEMBLY TO ENGINE STAND


    1. Install the engine assembly to an engine stand.

      Note


      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hanger from deforming or becoming damaged.

      • 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.

  104. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A000R6F

      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.