ENGINE ASSEMBLY REMOVAL

PROCEDURE

PRECAUTION
CAUTION:
- 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.
- 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.
RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

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DISCHARGE FUEL SYSTEM PRESSURE

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REMOVE SERVICE PLUG GRIP

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ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
SECURE STEERING WHEEL

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REMOVE FRONT WHEELS
REMOVE FRONT LOWER BUMPER ABSORBER (w/ Front Lower Bumper Absorber)
1. Remove the 6 bolts, 6 screws and front lower bumper absorber.
REMOVE FRONT WHEEL OPENING EXTENSION PAD RH
1. Remove the 3 screws and front wheel opening extension pad RH.
REMOVE ENGINE UNDER COVER RH (w/o Front Lower Bumper Absorber)
1. Remove the 2 screws, 3 clips and engine under cover RH.
REMOVE ENGINE UNDER COVER RH (w/ Front Lower Bumper Absorber)
1. Remove the 3 clips and engine under cover RH.
REMOVE FRONT WHEEL OPENING EXTENSION PAD LH
1. Remove the 3 screws and front wheel opening extension pad LH.
REMOVE ENGINE UNDER COVER LH (w/o Front Lower Bumper Absorber)
1. Remove the 2 screws, 2 clips and engine under cover LH.
REMOVE ENGINE UNDER COVER LH (w/ Front Lower Bumper Absorber)
1. Remove the 2 clips and engine under cover LH.
REMOVE FRONT FENDER APRON SEAL LH
1. Remove the 2 bolts, clip and front fender apron seal LH.
REMOVE FRONT FENDER APRON SEAL RH
1. Remove the 2 bolts, clip and front fender apron seal RH.
DRAIN ENGINE OIL

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DRAIN COOLANT (for Engine)

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DRAIN COOLANT (for Inverter)

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DRAIN HYBRID TRANSAXLE FLUID

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REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY
1. Lift the rear of the No. 1 engine cover sub-assembly to detach it from the 2 pins.
2. Lift the front of the No. 1 engine cover sub-assembly to detach it from the pin and remove it.
  
  Note
  
  Attempting to disengage both front and rear pins at the same time may cause the No. 1 engine cover sub-assembly to break.
REMOVE COOL AIR INTAKE DUCT SEAL

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REMOVE CONNECTOR COVER ASSEMBLY

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CHECK TERMINAL VOLTAGE

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TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

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REMOVE INLET AIR CLEANER ASSEMBLY
1. Remove the 2 bolts and inlet air cleaner assembly.
REMOVE AIR CLEANER CAP SUB-ASSEMBLY

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REMOVE AIR CLEANER FILTER ELEMENT
1. Remove the air cleaner filter element from the air cleaner case sub-assembly.
REMOVE AIR CLEANER CASE SUB-ASSEMBLY
1. Text in Illustration
  
  *a Projection
  
  Remove the 2 bolts and air cleaner case sub-assembly.
REMOVE NO. 5 INVERTER BRACKET

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REMOVE NO. 4 INVERTER BRACKET

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REMOVE UPPER INVERTER COVER

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DISCONNECT GENERATOR CABLE

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REMOVE UPPER INVERTER COVER

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DISCONNECT MOTOR CABLE

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REMOVE NO. 3 MOTOR CABLE BRACKET

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REMOVE CONNECTOR COVER ASSEMBLY

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DISCONNECT NO. 4 ENGINE WIRE

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DISCONNECT FRAME WIRE

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TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

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DISCONNECT LOW VOLTAGE CONNECTOR

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DISCONNECT NO. 3 ENGINE ROOM WIRE

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REMOVE NO. 4 INVERTER COOLING HOSE

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REMOVE NO. 1 INVERTER COOLING HOSE ASSEMBLY

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REMOVE INVERTER WITH CONVERTER ASSEMBLY

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DISCONNECT NO. 4 ENGINE WIRE
1. Disengage the 2 wire harness clamps to disconnect the No. 4 engine wire from the fan shroud.
DISCONNECT ENGINE WIRE
1. Remove the No. 1 relay block cover.
2. Disconnect the 4 connectors and disengage the wire harness clamp.
3. Remove the 2 bolts and disconnect the wire harness and wire harness bracket from the body.
4. Pull up the lever to disconnect the ECM connector.
5. Disengage the wire clamp.
DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
1. Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.
2. Using a screwdriver, disengage the 4 claws and disconnect the transmission control cable assembly with clip from the No. 1 transmission control cable bracket.
3. Remove the clip from the transmission control cable assembly.
4. Disconnect the transmission control cable assembly from the 2 transmission control brackets.
DISCONNECT NO. 1 RADIATOR HOSE
1. Remove the hose clamp to disconnect the air fuel ratio sensor wire from the No. 1 radiator hose.
2. Slide the clip and disconnect the No. 1 radiator hose.
DISCONNECT NO. 2 RADIATOR HOSE
1. Slide the clip and disconnect the No. 2 radiator hose.
DISCONNECT NO. 5 INVERTER COOLING HOSE
1. Slide the clip and disconnect the No. 5 inverter cooling hose from the hybrid vehicle transaxle assembly.
DISCONNECT INLET HEATER WATER HOSE
1. Slide the clip and disconnect the inlet heater water hose.
DISCONNECT OUTLET HEATER WATER HOSE
1. Slide the clip and disconnect the outlet heater water hose.
DISCONNECT FUEL TUBE SUB-ASSEMBLY

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REMOVE NO. 2 ENGINE MOUNTING STAY RH
1. Remove the 2 bolts and No. 2 engine mounting stay RH.
DISCONNECT EARTH WIRE
1. Remove the bolt to disconnect the earth wire from the engine moving control rod bracket.
REMOVE ENGINE MOVING CONTROL ROD BRACKET
1. Remove the 4 bolts and engine moving control rod bracket.
REMOVE ENGINE MOVING CONTROL ROD
1. Remove the bolt and engine moving control rod and No. 3 engine mounting stay RH from the engine moving control rod bracket.
  
  Tech Tips
  
  Perform this procedure only when replacement of the engine moving control rod is necessary.
DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

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DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

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REMOVE FRONT EXHAUST PIPE ASSEMBLY

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SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

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REMOVE FRONT AXLE SHAFT NUT LH

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REMOVE FRONT AXLE SHAFT NUT RH

Tech Tips

Use the same procedure described for the LH side.
SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

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SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

Tech Tips

Use the same procedure described for the LH side.
SEPARATE FRONT SPEED SENSOR LH

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SEPARATE FRONT SPEED SENSOR RH

Tech Tips

Use the same procedure described for the LH side.
SEPARATE TIE ROD ASSEMBLY LH

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SEPARATE TIE ROD ASSEMBLY RH

Tech Tips

Use the same procedure described for the LH side.
SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

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

Tech Tips

Use the same procedure described for the LH side.
SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH

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SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

Tech Tips

Use the same procedure described for the LH side.
REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

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REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

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REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

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REMOVE FLYWHEEL HOUSING UNDER COVER
1. Remove the flywheel housing under cover.
REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
1. 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.
  
  Text in Illustration
  
  Attachment Installation Position
  Note
  
  Install a height adjustment attachment and plate lift attachment under the engine assembly with transaxle.
  
  Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
  
  To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle.
  
  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 coolant leaks, do not position the height adjustment attachments or plate lift attachments under the No. 2 motor water jacket cover assembly.
  
  Text in Illustration
  
  *1 No. 2 Motor Water Jacket Cover Assembly
2. Text in Illustration
  
  *a Nut
  
  Remove the 4 bolts, 2 nuts, frame side rail plate RH and frame side rail plate LH.
3. Remove the 4 bolts, 2 nuts, front suspension member brace rear RH and front suspension member brace rear LH.
4. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.
  Note
  - Make sure that the engine assembly is clear of all wiring and hoses.
  - While lowering the engine assembly from the vehicle, do not allow it to contact the vehicle.
5. Install the engine hangers Click here.
6. Using an engine sling device and engine lift, secure the engine assembly.
DISCONNECT WIRE HARNESS

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REMOVE ENGINE WIRE
1. Remove the engine wire from the engine assembly.
REMOVE FRONT FRAME ASSEMBLY
1. Remove the bolt to disconnect the wire harness clamp bracket from the front frame assembly.
2. Disengage the 2 clamps to disconnect the No. 4 engine wire from the front engine mounting insulator.
3. Remove the nut and separate the engine mounting insulator LH.
4. Remove the bolt and separate the front engine mounting insulator.
5. Remove the nut and separate the engine mounting insulator RH.
6. Remove the front frame assembly.
7. Using height adjustment attachments and plate lift attachments, place the engine assembly on a flat level surface.
  Note
  - Using a height adjustment attachment and plate lift attachment, place the engine assembly with transaxle horizontally.
  - To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle.
  - Using an engine sling device and engine lift, secure the engine assembly before service.
REMOVE FRONT ENGINE MOUNTING INSULATOR
1. Remove the 3 nuts and front engine mounting insulator.
  
  Tech Tips
  
  Perform this procedure only when replacement of the front engine mounting insulator is necessary.
REMOVE ENGINE MOUNTING INSULATOR LH
1. Remove the 2 hole plugs from the front frame assembly.
2. Remove the 3 nuts and engine mounting insulator LH.
  
  Tech Tips
  
  Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
REMOVE ENGINE MOUNTING INSULATOR RH
1. Remove the 2 hole plugs from the front frame assembly.
2. Remove the 3 nuts and engine mounting insulator RH.
  
  Tech Tips
  
  Perform this procedure only when replacement of the engine mounting insulator RH is necessary.
REMOVE ENGINE MOUNTING BRACKET RH
1. Remove the 3 bolts and engine mounting bracket RH.
REMOVE DRIVE SHAFT BEARING BRACKET
1. Remove the 3 bolts and drive shaft bearing bracket.
REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

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REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

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REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

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REMOVE FLYWHEEL SUB-ASSEMBLY

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INSTALL ENGINE STAND
1. Install the engine assembly to an engine stand.