ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transaxle 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. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM


  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. 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

  4. REMOVE NO. 3 DECK BOARD SUB-ASSEMBLY (w/ Spare Tire)

    Click here

  5. REMOVE REAR DECK FLOOR BOX (w/ Spare Tire)

    Click here

  6. REMOVE DECK FLOOR BOX LH (w/ Spare Tire)

    Click here

  7. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  8. REMOVE BATTERY SERVICE HOLE COVER

    Click here

  9. REMOVE HYBRID BATTERY SERVICE PLUG COVER

    Click here

  10. REMOVE SERVICE PLUG GRIP

    Click here

  11. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  12. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY


    1. B002KWK

      Remove the 2 screws, 4 bolts, 10 clips and No. 1 engine under cover assembly.

  13. REMOVE REAR ENGINE UNDER COVER RH


    1. B002HWA

      Remove the 2 clips and rear engine under cover RH.

  14. REMOVE REAR ENGINE UNDER COVER LH


    1. B002HAP

      Remove the 2 clips and rear engine under cover LH.

  15. REMOVE FRONT FLOOR COVER CENTER LH

    Click here

  16. DRAIN ENGINE COOLANT

    Click here

  17. DRAIN ENGINE OIL

    Click here

  18. DRAIN COOLANT (for Inverter Coolant)

    Click here

  19. DRAIN HYBRID TRANSAXLE FLUID

    Click here

  20. REMOVE RADIATOR SUPPORT OPENING COVER

    Click here

  21. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. B002H73

      Remove the 3 pins and the No. 1 engine cover sub-assembly.

      Note

      Be sure to lift the No. 1 engine cover sub-assembly upwards when removing. Pulling the No. 1 engine cover sub-assembly towards you may damage the No. 1 engine cover sub-assembly.

  22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  23. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

  24. REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. B002IGY

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

  25. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

  26. DISCONNECT NO. 2 FLOOR WIRE

    CAUTION:

    Be sure to wear insulated gloves.

    Note

    Wrap insulation tape round the removed terminals to insulate them.


    1. B002JZ4C02
      *A for 2WD
      *B for AWD

      Disconnect the 2 clamps and No. 2 floor wire from the inverter bracket.

    2. B002JY3

      Remove the bolt.

    3. B002HKS

      Disconnect the 2 clamps and No. 2 floor wire from the hybrid vehicle transaxle assembly.

  27. REMOVE INVERTER WATER PUMP WITH MOTOR ASSEMBLY


    1. B002K3C

      Remove the 2 bolts and the inverter water pump with motor assembly from the inverter bracket.

  28. REMOVE INVERTER BRACKET ASSEMBLY


    1. B002K7N

      Remove the 5 bolts and inverter bracket assembly.

  29. REMOVE ECM

    Click here

  30. DISCONNECT RADIATOR RESERVOIR ASSEMBLY


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

  31. REMOVE FAN AND GENERATOR V BELT

    Click here

  32. DISCONNECT NO. 2 RADIATOR HOSE


    1. B002IBG

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

  33. REMOVE RADIATOR HOSE HOSE CLAMP


    1. B002K1HC02
      *a Push

      Remove the radiator hose hose clamp.

  34. DISCONNECT NO. 1 RADIATOR HOSE


    1. B002H30

      Slide the hose clip and disconnect the No. 1 radiator hose from the cylinder head sub-assembly.

  35. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  36. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  37. REMOVE NO. 3 INVERTER COOLING HOSE


    1. B002IV2

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

  38. REMOVE NO. 5 INVERTER COOLING HOSE


    1. B002HLK

      Slide the hose clip and remove the No. 5 inverter cooling hose from the motor cooling cooler.

  39. DISCONNECT GROUND WIRE


    1. B002IU1

      Remove the bolt, detach the 2 wire harness clamps and disconnect the ground wire.

  40. DISCONNECT WIRE HARNESS


    1. B002HKT

      Remove the bolt, detach the 3 wire harness clamps and disconnect the wire harness.

    2. B002ISM

      Remove the nut.

    3. Disconnect the 3 connectors and detach the 2 claws to disconnect the wire harness from the No. 1 engine room relay block.

    4. B002I6V

      Disconnect the terminal from the No. 1 engine room relay block side cover as shown in the illustration.

  41. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  42. DISCONNECT HEATER WATER INLET HOSE


    1. B002ILA

      Slide the hose clamp and disconnect the heater water inlet hose from the cylinder head sub-assembly.

  43. DISCONNECT HEATER WATER OUTLET HOSE


    1. B002JC7

      w/ EGR System:

      Slide the hose clamp and disconnect the heater water outlet hose from the No. 1 EGR pipe.

    2. w/o EGR System:

      Slide the hose clamp and disconnect the heater water outlet hose from the No. 3 water by-pass pipe.

  44. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. B002JT8

      Detach the clamp and disconnect the transmission control cable assembly from the bracket.

    2. Remove the 2 bolts and disconnect the transmission control cable assembly from the hybrid vehicle transaxle assembly and rear engine mounting insulator.

    3. B002IFN

      Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.

    4. Remove the clip and disconnect the transmission control cable assembly from the control cable bracket.

  45. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  46. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  47. DISCONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  48. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  49. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure described for the LH side.

  50. DISCONNECT FRONT SPEED SENSOR LH


  51. DISCONNECT FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  52. DISCONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  53. DISCONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  54. DISCONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  55. DISCONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  56. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

    Click here

  57. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  58. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  59. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  60. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  61. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. B002KC1

      Remove the flywheel housing under cover.

  62. REMOVE FRONT EXHAUST PIPE SUB-ASSEMBLY

    Click here

  63. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  64. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  65. INSTALL ENGINE HANGER


    1. B002HAVC01
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

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

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

      Tech Tips

      No. 1 Engine Hanger 12281-36020
      No. 2 Engine Hanger 12282-36021
      Bolt

      91552-81025

      91552-81040

  66. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. B002I5P

      Remove the 6 bolts and front crossmember sub-assembly.

    2. B002HIP

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

      Note

      While holding the nut in place, loosen the through bolt.

    3. Set an engine lifter underneath the engine.

      Note


      • Place the engine on wooden blocks or equivalent so that the engine is level.

      • B002HSMC02
        *1 No. 2 Motor Water Jacket Cover Assembly

        To prevent coolant leaks, do not position the height adjustment attachments or plate lift attachments under the No. 2 motor water jacket cover assembly.

    4. B002KB3

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

    5. B002HMN

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

    6. B002KJ3

      Remove the 6 bolts, front suspension member rear brace RH and front suspension member rear brace LH.

    7. B002HTF

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

    8. Operate the engine lifter and 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.

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

    10. B002J3O

      Remove the through bolt, nut and front suspension crossmember sub-assembly from the engine with transaxle.

      Note

      Do not damage any engine or transaxle components.

      Tech Tips

      Raise the engine with transaxle assembly while keeping it level.

  67. DISCONNECT WIRE HARNESS

    Click here

  68. REMOVE TRANSMISSION OIL COOLER ASSEMBLY

    Click here

  69. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

    Click here

  70. FIX ENGINE ASSEMBLY


    1. Using wooden blocks or plate lift attachments, set the engine on a flat surface.

      Note


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

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

      • Perform this step while supporting the engine assembly using a sling device and chain block.

  71. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

    Click here

  72. REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  73. REMOVE ENGINE WIRE

  74. INSTALL ENGINE TO ENGINE STAND

    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.


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

    2. Remove the 2 bolts and 2 engine hangers.

  75. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B002KA6

      Remove the 2 bolts, 2 nuts and rear engine mounting insulator.

  76. 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. B002KE1

      Remove the bolt and radiator reservoir bracket.

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

  77. REMOVE ENGINE MOUNTING SPACER

    Tech Tips

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


    1. B002K37

      Remove the 2 bolts and engine mounting spacer.

  78. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B002HO4

      Remove the 4 bolts and engine mounting insulator LH.

  79. REMOVE DRIVE SHAFT BEARING BRACKET


    1. B002HV6

      Remove the 3 bolts and drive shaft bearing bracket.