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. REMOVE ENGINE ROOM SIDE COVER


    1. A000SGZ

      Remove the 4 clips and engine room side cover.

  2. REMOVE COOL AIR INTAKE DUCT SEAL


    1. A000SRD

      Remove the 7 clips and cool air intake duct seal.

  3. REMOVE V-BANK COVER SUB-ASSEMBLY


    1. A000SCUE01

      Place both hands on the sides of the cover as shown in the illustration, lift the cover to detach the 2 clips near the front in the order shown in the illustration, and then lift the cover further to detach the rear clip and remove the cover.

      Text in Illustration
      B002BQR Areas to place hands when lifting cover

      Note

      If the cover is lifted rearward or forward and to the right or left at the same time, the cover may be damaged.

  4. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM (for HFC-134a(R134a))

    Click here

  5. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  6. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  7. REMOVE LUGGAGE COMPARTMENT FLOOR MAT

    Click here

  8. REMOVE LUGGAGE COMPARTMENT TRIM COVER LH

    Click here

  9. 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 auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the auxiliary battery terminal notice before proceeding with work Click here.

  10. 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.

  11. REMOVE NO. 1 SEAT ARMREST CAP

    Click here

  12. REMOVE LOWER HYBRID VEHICLE BATTERY COVER PANEL

    Click here

  13. REMOVE SERVICE PLUG GRIP

    Click here

  14. REMOVE INVERTER COVER

    Click here

  15. REMOVE CONNECTOR COVER ASSEMBLY

    Click here

  16. CHECK TERMINAL VOLTAGE

    Click here

  17. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

    Click here

  18. REMOVE INVERTER MOTOR CABLE BRACKET ASSEMBLY

    Click here

  19. REMOVE INVERTER TERMINAL COVER

    Click here

  20. REMOVE FRONT WHEEL

  21. REMOVE ENGINE UNDER COVER


    1. A000PXW

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

  22. REMOVE REAR ENGINE UNDER COVER LH


    1. A000S8Z

      Remove the screw and rear engine under cover LH.

  23. REMOVE REAR ENGINE UNDER COVER RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  24. REMOVE FRONT SUSPENSION MEMBER BRACE


    1. A000OLZ

      w/ Canister Pump Module:

      Remove the 6 bolts and front suspension member brace.

    2. A000SQG

      w/o Canister Pump Module:

      Remove the 4 bolts, and then turn the clip and remove the front suspension member brace.

      Tech Tips

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

  25. REMOVE NO. 2 ENGINE UNDER COVER


    1. A000SS0

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

  26. DRAIN ENGINE OIL

    Click here

  27. DRAIN ENGINE COOLANT

    Click here

  28. DRAIN COOLANT (for Inverter)

    Click here

  29. REMOVE NO. 1 AIR CLEANER INLET


    1. A000PH5

      Remove the bolt and No. 1 air cleaner inlet.

  30. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  31. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  32. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A000PJZ

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

      Note

      When removing the air cleaner case sub-assembly, be careful not to lose the grommet on the underside of the air cleaner case.

  33. DISCONNECT WIRE HARNESS

    Click here

  34. REMOVE OIL PUMP MOTOR CONTROLLER

    Click here

  35. REMOVE WIRING HARNESS PROTECTOR

    Click here

  36. REMOVE HEATER ACCESSORY ASSEMBLY

    Click here

  37. DISCONNECT PURGE LINE HOSE


    1. A000NG8

      Remove the clamp and disconnect the purge line hose.

  38. DISCONNECT NO. 3 FUEL TUBE SUB-ASSEMBLY


    1. A000NDT

      Disconnect the No. 3 fuel tube sub-assembly Click here.

  39. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY


    1. A000RRQ

      Disconnect the No. 2 fuel tube sub-assembly Click here.

  40. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A000Q0G

      Disconnect the fuel tube sub-assembly Click here.

  41. REMOVE NO. 1 RADIATOR HOSE

    Click here

  42. DISCONNECT NO. 2 RADIATOR HOSE

    Click here

  43. DISCONNECT INLET HEATER WATER HOSE


    1. A000QEL

      Remove the water hose set.

    2. A000NH9

      Disconnect the inlet heater water hose.

  44. DISCONNECT OUTLET HEATER WATER HOSE


    1. A000QXO

      Remove the water hose set.

    2. A000NMC

      Disconnect the outlet heater water hose.

  45. DISCONNECT AIR CONDITIONING HARNESS


    1. A000O8UE01
      Text in Illustration
      *1 Green-colored Lock

      Release the green-colored lock and disconnect the connector as shown in the illustration.

      CAUTION:

      Wear insulated gloves when performing the procedure.

      Note

      Insulate the connector by sealing it with tape.

    2. A000S7P

      Remove the bolt and 3 wire harness clamps to disconnect the air conditioning harness.

  46. DISCONNECT NO. 2 OIL COOLER INLET HOSE

    Click here

  47. DISCONNECT NO. 2 OIL COOLER OUTLET HOSE

    Click here

  48. DISCONNECT NO. 5 INVERTER COOLING HOSE (for LHD)


    1. A000NZ1

      Disconnect the No. 5 inverter cooling hose.

  49. DISCONNECT NO. 2 MOTOR COOLING HOSE (for RHD)


    1. A000SDU

      Disconnect the No. 2 motor cooling hose.

  50. REMOVE NO. 1 INVERTER COOLING PIPE (for LHD)


    1. A000SK0

      Disconnect the 2 connectors, 2 wire harness clamps and wire harness.

    2. A000ON7

      Remove the bolt and disconnect the 2 hoses to remove the No. 1 inverter cooling pipe.

  51. DISCONNECT NO. 7 INVERTER COOLING HOSE (for RHD)


    1. A000T1Q

      Disconnect the No. 7 inverter cooling hose.

  52. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  53. DISCONNECT SUCTION HOSE

    Click here

  54. REMOVE ECM

    Click here

  55. DISCONNECT MOTOR CABLE

    Click here

  56. DISCONNECT GENERATOR CABLE

    Click here

  57. REMOVE INVERTER RESERVOIR TANK ASSEMBLY (for LHD)

    Click here

  58. REMOVE INVERTER RESERVOIR TANK ASSEMBLY (for RHD)

    Click here

  59. DISCONNECT ENGINE WIRE


    1. Engine Room LH Side:


      1. Remove the No. 1 engine room relay block cover.

      2. A000SF2

        Disconnect the 3 connectors from the No. 2 connector holder.

      3. A000NF0

        Detach the clamp and 3 claws, and then disconnect the No. 2 connector holder.

    2. Engine Room RH Side:


      1. A000OPS

        Remove the bolt, clamp and No. 3 engine wire.

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

    Click here

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

    Click here

  62. REMOVE FRONT CENTER FLOOR BRACE

    Click here

  63. DISCONNECT HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)

    Click here

  64. DISCONNECT HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)

    Click here

  65. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  66. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY

    Click here

  67. REMOVE FRONT CENTER FLOOR BRACE SUB-ASSEMBLY


    1. A000QYL

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

  68. REMOVE NO. 1 FUEL TANK PROTECTOR

    Click here

  69. REMOVE FRONT NO. 1 FLOOR HEAT INSULATOR

    Click here

  70. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  71. DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (w/o VGRS)

    Click here

  72. DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (w/ VGRS)

    Click here

  73. 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.

  74. DISCONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  75. DISCONNECT FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

  76. DISCONNECT FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  77. DISCONNECT POWER STEERING LINK WIRE HARNESS


    1. A000QTHE01

      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.

  78. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  79. REMOVE FRONT NO. 2 UPPER SUSPENSION MEMBER


    1. A000RH9

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

  80. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. A000SQA

      Remove the 4 bolts and suspension member protector.

  81. INSTALL ENGINE HANGER


    1. A000NPDE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the 2 No. 1 engine hangers with the 4 bolts as shown in the illustration.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

      Tech Tips

      No. 1 engine hanger 12281 - 31130
      No. 2 engine hanger 12282 - 31140
      Bolt 91671 - F0822

  82. REMOVE ENGINE AND TRANSMISSION ASSEMBLY


    1. A000N8Q

      Remove the nut and disconnect the wire harness.

    2. A000PROE01
      Text in Illustration
      *a Place Wooden Block or Plate Attachments

      Set the engine on an engine lifter.

      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.

    3. A000QZY

      Remove the 4 bolts, and then disconnect the rear engine mounting member.

    4. A000Q65

      Remove the 10 bolts and 2 nuts shown in the illustration.

      Text in Illustration
      B002B6O Bolt
      B002BBR Nut

    5. Operate the engine lifter, and then slowly remove the engine from the vehicle.

      Note


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

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

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

      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.

  83. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  84. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A000NUO

      Remove the bolt and engine oil level dipstick guide.

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

  85. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY LH


    1. Remove the engine under cover sub-assembly LH.

  86. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY RH


    1. Remove the engine under cover sub-assembly RH.

  87. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  88. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  89. REMOVE CONNECTOR

    Click here

  90. REMOVE WIRE HARNESS

    Click here

  91. REMOVE OIL COOLER HOSE TUBE SUB-ASSEMBLY

    Click here

  92. REMOVE WATER PIPE AND HOSE SUB-ASSEMBLY

    Click here

  93. REMOVE TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

    Click here

  94. SUPPORT HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here

  95. REMOVE STARTER HOLE INSULATOR

    Click here

  96. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  97. REMOVE HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here

  98. REMOVE TRANSMISSION INPUT DAMPER COVER ASSEMBLY

    Click here

  99. REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  100. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  101. REMOVE FAN AND GENERATOR V BELT

    Click here

  102. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A000R29E01
      Text in Illustration
      *a LH Side
      *b RH Side

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

  103. INSTALL ENGINE ON ENGINE STAND


    1. Install the engine to an engine stand with 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 4 bolts and 2 engine hangers.

  104. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A000QDFE01
      Text in Illustration
      *a LH Side
      *b RH Side

      Remove the 2 nuts and front engine mounting insulator RH and LH.

  105. REMOVE REAR ENGINE MOUNTING MEMBER


    1. A000QRX

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

  106. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A000PUL

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