ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during engine assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure Necessary Procedure Effect/Inoperative Function when Necessary Procedure not Performed Link
Auxiliary battery terminal is disconnected/reconnected Memorize steering angle neutral point Lane departure alert system (w/ Steering Control)

Click here

Intelligent clearance sonar system*1
Simple advanced parking guidance system*1
Pre-collision system
Adaptive high beam system
Parking assist monitor system

Click here

Initialize back door lock Power door lock control system

Click here

Replacement of inverter with converter assembly Resolver learning

  • DTCs are stored

  • Slight vibration at a vehicle speed of 5 km/h (3 mph) or less

  • Shock or vibration during acceleration

Click here

Replacement of ECM Perform Vehicle Identification Number (VIN) registration (w/ Canister Pump Module) MIL comes on

Click here

Perform Vehicle Identification Number (VIN) or frame number registration (w/o Canister Pump Module)

Click here


    for SFI system (w/ Canister Pump Module)

  • Replacement of throttle body assembly

  • Replacement of engine assembly

  • Gas leak from exhaust system is repaired

 Inspection After Repair

  • Poor idle, etc.

  • Engine start function, etc.

Click here


    for SFI system (w/o Canister Pump Module)

  • Replacement of throttle body assembly

  • Replacement of engine assembly

  • Gas leak from exhaust system is repaired

 Inspection After Repair

  • Poor idle, etc.

  • Engine start function, etc.

Click here

Suspension, tires, etc.

(The vehicle height changes because of suspension or tire replacement)

  • Ultrasonic sensor detection angle

  • Ultrasonic sensor detection angle registration

  • Intelligent clearance sonar system

  • Simple advanced parking guidance system

Click here

Rear television camera assembly optical axis (Back camera position setting) Parking assist monitor system

Click here

Initialize No. 1 headlight ECU sub-assembly LH

  • Automatic headlight beam level control system

  • Adaptive high beam system*2

Click here

Front wheel alignment adjustment

  1. Clear zero point calibration data.

  2. Perform yaw rate and acceleration sensor zero point calibration.

  • DTCs are stored

  • ABS warning light illuminates

  • Brake warning light/yellow (minor malfunction) illuminates

  • Slip indicator light illuminates

  • VSC disabled or malfunctions

Click here

Replacement of hybrid vehicle transaxle assembly

  • Resolver learning

  • Initialize resolver

  • DTCs are stored

  • Slight vibration at a vehicle speed of 5 km/h (3 mph) or less

  • Shock or vibration during acceleration

Click here

*1: When performing learning using the GTS.

Click here

*2: w/ Adaptive High Beam System

CAUTION:


  • B006J7EC01
    *a An Object Exceeding Weight Limit of Engine Lifter

    The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.

  • B006IVY

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

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.

    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. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  4. SECURE STEERING WHEEL

    Click here

  5. REMOVE FRONT WHEELS

    Click here

  6. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY


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

  7. REMOVE REAR ENGINE UNDER COVER LH


    1. except Rough Road Area Specification Vehicles:


      1. Remove the 4 clips, screw and rear engine under cover LH.

    2. for Rough Road Area Specification Vehicles:


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

  8. REMOVE REAR ENGINE UNDER COVER RH


    1. except Rough Road Area Specification Vehicles:


      1. Remove the 4 clips, screw and rear engine under cover RH.

    2. for Rough Road Area Specification Vehicles:


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

  9. REMOVE NO. 2 ENGINE UNDER COVER


    1. Remove the 3 bolts and No. 2 engine under cover.

  10. DRAIN ENGINE OIL

    Click here

  11. DRAIN ENGINE COOLANT (for Engine)

    Click here

  12. DRAIN HYBRID TRANSAXLE FLUID

    Click here

  13. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. Disengage the 3 clips in the order shown in the illustration to remove the No. 1 engine cover sub-assembly.

      B006HK0C02
      B006IOI Areas to be Held when Lifting No. 1 Engine Cover Sub-assembly B006IFV Remove in this Direction

      Note


      • Pull the No. 1 engine cover sub-assembly straight up to remove. Attempting to pull the No. 1 engine cover sub-assembly forward or attempting to pull it up by holding the left and right sides may cause the No. 1 engine cover sub-assembly to break.

      • If the clips are not disengaged in the order shown in the illustration, the No. 1 engine cover sub-assembly may be damaged.

  14. DISCONNECT NO. 8 WATER BY-PASS HOSE


    1. B006HAT

      Slide the clip and disconnect the No. 8 water by-pass hose from the No. 2 water by-pass hose assembly.

  15. REMOVE RADIATOR SUPPORT OPENING COVER

    Click here

  16. REMOVE INLET NO. 2 AIR CLEANER

    Click here

  17. REMOVE THROTTLE BODY ASSEMBLY

    Click here

  18. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  19. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  20. REMOVE AIR CLEANER BRACKET

    Click here

  21. REMOVE INLET NO. 1 AIR CLEANER

    Click here

  22. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

  23. DISCONNECT NO. 3 RADIATOR HOSE


    1. B006HTN

      Remove the 2 bolts from the hybrid vehicle transaxle assembly.

    2. Slide the clip and disconnect the No. 3 radiator hose from the water outlet.

  24. DISCONNECT NO. 2 RADIATOR HOSE


    1. B006H84

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

  25. DISCONNECT OUTLET HEATER WATER HOSE E


    1. B006J2L

      Slide the clip and disconnect the outlet heater water hose E from the No. 1 water by-pass pipe.

  26. DISCONNECT INLET HEATER WATER HOSE A


    1. B006IRY

      Slide the clip and disconnect the inlet heater water hose A from the EGR valve assembly.

  27. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. B006H7I

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

  28. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  29. DISCONNECT INLET HYBRID RADIATOR HOSE


    1. B006HGL

      Slide the clip and disconnect the inlet hybrid radiator hose from the motor cooling cooler.

  30. DISCONNECT OUTLET NO. 1 HYBRID WATER PUMP HOSE


    1. B006J2N

      Slide the clip and disconnect the outlet No. 1 hybrid water pump hose from the motor cooling cooler.

  31. SEPARATE COMPRESSOR WITH MOTOR ASSEMBLY


    1. B006ICGC01
      *a Bracket

      Remove the bolt and disconnect the bracket.

    2. B006IIBC02
      *a Connector (A)
      *b Connector (B)
      *c Green-colored Lock

      Using a screwdriver, slide the green-colored lock of the connector (A) as shown in the illustration to release it and disconnect the connector.

      CAUTION:

      Make sure to wear insulated gloves.

      Note

      Insulate the disconnected terminals and connector with insulating tape.

    3. Disconnect the connector (B).

    4. Type A:


      1. B006IEH

        Remove the bolt and 2 nuts.

      2. B006ISZ

        Using an E8 "TORX" socket wrench, remove the 2 stud bolts and compressor with motor assembly.

    5. Type B:


      1. B006HKA

        Remove the 3 bolts and separate the compressor with motor assembly.

  32. DISCONNECT NO. 3 ENGINE WIRE


    1. B006IOJ

      Disengage the clamp.

    2. Remove the bolt and disconnect the No. 3 engine wire from the hybrid vehicle transaxle assembly.

  33. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  34. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  36. REMOVE FRONT FLOOR COVER LH

    Click here

  37. REMOVE FRONT FLOOR COVER RH

    Tech Tips

    Use the same procedure as for the LH side.

  38. REMOVE FRONT CENTER FLOOR BRACE

    Click here

  39. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

    Click here

  40. DISCONNECT INLET NO. 1 OIL COOLER HOSE


    1. B006HOM

      Slide the clip and disconnect the inlet No. 1 oil cooler hose from the hybrid vehicle transaxle assembly.

  41. DISCONNECT OUTLET NO. 1 OIL COOLER HOSE


    1. B006J7S

      Slide the clip and disconnect the outlet No. 1 oil cooler hose from the hybrid vehicle transaxle assembly.

  42. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  43. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure as for the LH side.

  44. SEPARATE FRONT SPEED SENSOR LH

    Click here

  45. SEPARATE FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure as for the LH side.

  46. SEPARATE TIE ROD END SUB-ASSEMBLY LH

    Click here

  47. SEPARATE TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  48. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  49. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  50. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

    Click here

  51. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  52. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  53. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  54. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  55. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  56. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING

    Click here

  57. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  58. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  59. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. B006IA3C01
      B006IOI 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 transaxle and front suspension crossmember sub-assembly.

      Note


      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle and front suspension crossmember sub-assembly level.

      • 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 to or removed from an engine stand.

    2. B006J8Z

      Remove the bolt and nut to disconnect the 2 cooler brackets.

    3. B006IUU

      Remove the nut.

    4. Remove the 2 bolts and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.

    5. B006HR8

      Remove the 3 bolts and nut to separate the engine mounting insulator LH from the hybrid vehicle transaxle assembly.

    6. B006HYJ

      Remove the bolt and No. 2 engine mounting stay LH.

    7. B006J7Q

      Remove the 4 bolts and separate the front suspension crossmember sub-assembly from the vehicle body.

    8. Operate the engine lifter to remove the engine assembly with transaxle from the vehicle body.

      Note


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

      • While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle body.

  60. REMOVE WIRING HARNESS CLAMP BRACKET


    1. B006HL5

      Disengage the 3 clamps.

    2. Remove the bolt and wiring harness clamp bracket from the cylinder head sub-assembly.

  61. INSTALL ENGINE HANGERS


    1. B006J07C01
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      *3 Bolt

      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 }

      Tech Tips

      No. 1 Engine Hanger 12281-37021
      No. 2 Engine Hanger 12282-37011
      Bolt 91552-81050

    2. Using an engine sling device and engine lifter, secure the engine assembly with transaxle.

      Note


      • Adjust the angle of the sling device carefully to prevent damage or deformation to the engine hangers or engine assembly.

      • 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 to or removed from an engine stand.

  62. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B006HOC

      Remove the 4 bolts, nut and engine mounting insulator LH from the vehicle body.

  63. 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. B006IJ5

      Remove the 2 bolts and No. 2 earth wire from the engine mounting insulator sub-assembly RH and vehicle body.

    2. B006HE5

      Remove the 2 bolts, nut and engine mounting insulator sub-assembly RH from the vehicle body.

  64. REMOVE STARTER HOLE INSULATOR

    Click here

  65. REMOVE ENGINE WIRE


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

  66. REMOVE ENGINE ASSEMBLY

    Click here

  67. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

    Click here

  68. REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  69. REMOVE ONE-WAY CLUTCH ASSEMBLY

    Click here

  70. REMOVE ONE-WAY CLUTCH HOLDING PLATE

    Click here

  71. 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 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.

  72. REMOVE ENGINE HANGERS


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