ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with hybrid vehicle 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.

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    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 .

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  2. DISCHARGE FUEL SYSTEM PRESSURE

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  3. REMOVE SERVICE PLUG GRIP

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  4. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  5. REMOVE FRONT WHEELS

  6. REMOVE FRONT LOWER BUMPER ABSORBER


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

  7. REMOVE NO. 1 ENGINE UNDER COVER


    1. Remove the 2 screws, 11 clips and No. 1 engine under cover.

  8. REMOVE CENTER NO. 4 ENGINE UNDER COVER (w/ Cover)


    1. Remove the 2 clips and center No. 4 engine under cover.

  9. REMOVE FRONT NO. 3 ENGINE UNDER COVER


    1. Remove the 4 clips and front No. 3 engine under cover.

  10. REMOVE REAR ENGINE UNDER COVER LH


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

  11. REMOVE REAR ENGINE UNDER COVER RH


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

  12. DRAIN ENGINE OIL

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  13. DRAIN ENGINE COOLANT (for Engine)

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  14. DRAIN COOLANT (for Inverter)

    Click here

  15. DRAIN HYBRID TRANSAXLE FLUID

    Click here

  16. REMOVE NO. 2 CYLINDER HEAD COVER


    1. A01SFO0N02

      Remove the 3 clips and No. 2 cylinder head cover.

      Note


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

      • When disengaging the clip (3), hold the end of the No. 2 cylinder head cover behind the 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 pull it up by holding the left and right ends may cause the No. 2 cylinder head cover to break.

  17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A01SFGG

      Disconnect the mass air flow meter connector.

    2. Disconnect the 2 clamps.

    3. Loosen the hose clamp and remove the air cleaner cap sub-assembly from the air cleaner case sub-assembly.

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

  18. REMOVE INLET AIR CLEANER ASSEMBLY


    1. A01SFI3

      Remove the 2 bolts and inlet air cleaner assembly.

  19. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A01SFLO

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

    2. Remove the 3 bolts and air cleaner case sub-assembly.

  20. REMOVE AIR CLEANER HOSE ASSEMBLY

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  21. REMOVE NO. 1 INVERTER BRACKET

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  22. REMOVE INVERTER COVER

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  23. CHECK TERMINAL VOLTAGE

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  24. DISCONNECT ENGINE ROOM MAIN WIRE

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  25. DISCONNECT FRAME WIRE

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  26. DISCONNECT GENERATOR CABLE

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  27. DISCONNECT MOTOR CABLE

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  28. DISCONNECT NO. 2 ENGINE WIRE

    Click here

  29. INSTALL INVERTER COVER

    Click here

  30. DISCONNECT NO. 2 ENGINE ROOM WIRE

    Click here

  31. DISCONNECT NO. 1 INVERTER COOLING HOSE

    Click here

  32. DISCONNECT NO. 6 INVERTER COOLING HOSE

    Click here

  33. REMOVE INVERTER WITH CONVERTER ASSEMBLY

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  34. REMOVE INVERTER RESERVE TANK ASSEMBLY


    1. A01SF7A

      Remove the 2 bolts and disconnect the inverter reserve tank assembly from the inverter tray bracket.

  35. REMOVE INVERTER TRAY BRACKET


    1. A01SFU0

      Disconnect the 2 clamps.

    2. Remove the 5 bolts and inverter tray bracket.

  36. DISCONNECT NO. 1 RADIATOR HOSE


    1. A01SFD6

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

  37. DISCONNECT NO. 2 RADIATOR HOSE


    1. A01SFC9

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

  38. DISCONNECT NO. 4 WATER BY-PASS HOSE


    1. A01SFO2

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

  39. DISCONNECT NO. 3 INVERTER COOLING HOSE


    1. A01SFHB

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

  40. DISCONNECT NO. 5 INVERTER COOLING HOSE


    1. A01SFAU

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

  41. DISCONNECT OUTLET HEATER WATER HOSE A


    1. A01SFLF

      Slide the clip and disconnect the outlet heater water hose A from the EGR cooler sub-assembly.

  42. DISCONNECT INLET HEATER WATER HOSE A


    1. A01SFAS

      Slide the clip and disconnect the inlet heater water hose A from the EGR cooler sub-assembly.

  43. DISCONNECT HEATER HOSE


    1. A01SFRJ

      Slide the clip and disconnect the heater hose from the EGR cooler sub-assembly.

  44. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. A01SFV0

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

  45. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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  46. SEPARATE COMPRESSOR WITH MOTOR ASSEMBLY

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  47. DISCONNECT WIRE HARNESS


    1. A01SFAA

      Disconnect the clamp.

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

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

    4. A01SFAE

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

    5. A01SFPB

      Disconnect the 3 clamps and wire harness from the engine room junction block.

    6. A01SFCZ

      Disconnect the 2 clamps and wire harness.

  48. SECURE STEERING WHEEL

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  49. REMOVE COLUMN HOLE COVER SILENCER SHEET

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  50. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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

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  52. REMOVE FRONT CENTER FLOOR BRACE

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  53. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst) (w/ Exhaust Heat Recirculation System)

    Click here

  54. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst) (w/o Exhaust Heat Recirculation System)

    Click here

  55. REMOVE FRONT DRIVE SHAFT ASSEMBLY

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  56. REMOVE ENGINE FRONT MOUNTING BRACKET LOWER REINFORCEMENT

    Click here

  57. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  58. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  59. REMOVE FRONT SUSPENSION MEMBER BRACE REAR LH

    Click here

  60. REMOVE FRONT SUSPENSION MEMBER BRACE REAR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  61. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY

    Click here

  62. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE ASSEMBLY


    1. Set an engine lifter.

      Note


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

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

      • Do not perform any procedure 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.

      Tech Tips

      Place the engine assembly with hybrid vehicle transaxle assembly on wooden blocks or equivalent so that the engine is level.

    2. A01SFTF

      Remove the 2 bolts and disconnect the front engine mounting insulator from the front cross member sub-assembly.

    3. A01SFGZ

      Remove the 4 bolts and front crossmember sub-assembly.

    4. A01SFDJ

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

    5. A01SFVG

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

      Tech Tips

      When removing the through bolt, keep the nut from rotating.

    6. Carefully remove the engine assembly with hybrid vehicle transaxle assembly from the vehicle.

      Note

      Make sure that the engine assembly with hybrid vehicle transaxle assembly is clear of all wiring and hoses.

  63. INSTALL ENGINE HANGER


    1. A01SFRPC01
      *1 No. 1 Engine Hanger (Part No.12281-37021)
      *2 No. 2 Engine Hanger (Part No.12282-37011)
      *3 Bolt (Part No.91552-81050)

      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 }

    2. Attach the sling device to the No. 1 engine hanger, No. 2 engine hanger and chain block.

  64. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A01SFOTC01
      *A Type A
      *B Type B

      Remove the through bolt, nut and front engine mounting insulator from the front engine mounting bracket.

      Tech Tips

      Because the nut has its own stopper, do not turn the nut. Loosen the through bolt with the nut secured.

  65. REMOVE REAR ENGINE MOUNTING INSULATOR


    1. A01SFBWC01
      *A Type A
      *B Type B

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

  66. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A01SFI7

      Remove the 4 bolts and engine mounting insulator LH.

  67. 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. A01SFIP

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

    2. A01SFLXN03

      Remove the bolt (A) and cooler pipe clamp bracket from the engine mounting insulator sub-assembly RH.

    3. Disconnect the cooler pipe clamp from the engine mounting insulator sub-assembly RH.

    4. Remove the 3 bolts (B) and engine mounting insulator sub-assembly RH.

  68. REMOVE RADIATOR PIPE


    1. A01SFRE

      Remove the 2 bolts and disconnect the radiator pipe from the hybrid vehicle transaxle assembly.

    2. Slide the clip and disconnect the No. 3 radiator hose from the cylinder head sub-assembly.

  69. REMOVE STARTER HOLE INSULATOR

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  70. REMOVE FLYWHEEL HOUSING SIDE COVER

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  71. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly with hybrid vehicle transaxle assembly.

  72. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

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  73. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

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  74. REMOVE FLYWHEEL SUB-ASSEMBLY

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  75. INSTALL ENGINE 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 hangers from deforming or becoming damaged.

      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.

  76. REMOVE ENGINE HANGER


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