ENGINE ASSEMBLY REMOVAL

PROCEDURE

1. Click here

   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).

2. Click here

   RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

   Click here

3. Click here

   DISCHARGE FUEL SYSTEM PRESSURE

   (Click here)

4. Click here

   REMOVE SERVICE PLUG GRIP

   (Click here)

5. Click here

   ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

6. Click here

   SECURE STEERING WHEEL

   Click here

7. Click here

   REMOVE FRONT WHEELS

8. Click here

   REMOVE FRONT LOWER BUMPER ABSORBER (w/ Front Lower Bumper Absorber)

   
   

   1. Remove the 6 bolts, 6 screws and front lower bumper absorber.

9. Click here

   REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

   
   

   1. Remove the 3 screws and front wheel opening extension pad RH.

10. Click here

    REMOVE ENGINE UNDER COVER RH (w/o Front Lower Bumper Absorber)

    
    

    1. Remove the 2 screws, 3 clips and engine under cover RH.

11. Click here

    REMOVE ENGINE UNDER COVER RH (w/ Front Lower Bumper Absorber)

    
    

    1. Remove the 3 clips and engine under cover RH.

12. Click here

    REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

    
    

    1. Remove the 3 screws and front wheel opening extension pad LH.

13. Click here

    REMOVE ENGINE UNDER COVER LH (w/o Front Lower Bumper Absorber)

    
    

    1. Remove the 2 screws, 2 clips and engine under cover LH.

14. Click here

    REMOVE ENGINE UNDER COVER LH (w/ Front Lower Bumper Absorber)

    
    

    1. Remove the 2 clips and engine under cover LH.

15. Click here

    REMOVE FRONT FENDER APRON SEAL LH

    
    

    1. Remove the 2 bolts, clip and front fender apron seal LH.

16. Click here

    REMOVE FRONT FENDER APRON SEAL RH

    
    

    1. Remove the 2 bolts, clip and front fender apron seal RH.

17. Click here

    DRAIN ENGINE OIL

    Click here

18. Click here

    DRAIN COOLANT (for Engine)

    Click here

19. Click here

    DRAIN COOLANT (for Inverter)

    Click here

20. Click here

    DRAIN HYBRID TRANSAXLE FLUID

    Click here

21. Click here

    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.

22. Click here

    REMOVE COOL AIR INTAKE DUCT SEAL

    Click here

23. Click here

    REMOVE CONNECTOR COVER ASSEMBLY

    Click here

24. Click here

    CHECK TERMINAL VOLTAGE

    Click here

25. Click here

    TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

    Click here

26. Click here

    REMOVE INLET AIR CLEANER ASSEMBLY

    
    
    1. 

       Remove the 2 bolts and inlet air cleaner assembly.

27. Click here

    REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

28. Click here

    REMOVE AIR CLEANER FILTER ELEMENT

    
    

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

29. Click here

    REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    
    
    1. 

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

       Table 1. Text in Illustration

       *a	Projection

30. Click here

    REMOVE NO. 5 INVERTER BRACKET

    Click here

31. Click here

    REMOVE NO. 4 INVERTER BRACKET

    Click here

32. Click here

    REMOVE UPPER INVERTER COVER

    Click here

33. Click here

    DISCONNECT GENERATOR CABLE

    Click here

34. Click here

    REMOVE UPPER INVERTER COVER

    Click here

35. Click here

    DISCONNECT MOTOR CABLE

    Click here

36. Click here

    REMOVE NO. 3 MOTOR CABLE BRACKET

    Click here

37. Click here

    REMOVE CONNECTOR COVER ASSEMBLY

    Click here

38. Click here

    DISCONNECT NO. 4 ENGINE WIRE

    Click here

39. Click here

    DISCONNECT FRAME WIRE

    Click here

40. Click here

    TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

    Click here

41. Click here

    DISCONNECT LOW VOLTAGE CONNECTOR

    Click here

42. Click here

    DISCONNECT NO. 3 ENGINE ROOM WIRE

    Click here

43. Click here

    REMOVE NO. 4 INVERTER COOLING HOSE

    Click here

44. Click here

    REMOVE NO. 1 INVERTER COOLING HOSE ASSEMBLY

    Click here

45. Click here

    REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

46. Click here

    DISCONNECT NO. 4 ENGINE WIRE

    
    
    1. 

       Disengage the 2 wire harness clamps to disconnect the No. 4 engine wire from the fan shroud.

47. Click here

    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.

48. Click here

    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.

49. Click here

    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.

50. Click here

    DISCONNECT NO. 2 RADIATOR HOSE

    
    
    1. 

       Slide the clip and disconnect the No. 2 radiator hose.

51. Click here

    DISCONNECT NO. 5 INVERTER COOLING HOSE

    
    
    1. 

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

52. Click here

    DISCONNECT INLET HEATER WATER HOSE

    
    
    1. 

       Slide the clip and disconnect the inlet heater water hose.

53. Click here

    DISCONNECT OUTLET HEATER WATER HOSE

    
    
    1. 

       Slide the clip and disconnect the outlet heater water hose.

54. Click here

    DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

55. Click here

    REMOVE NO. 2 ENGINE MOUNTING STAY RH

    
    
    1. 

       Remove the 2 bolts and No. 2 engine mounting stay RH.

56. Click here

    DISCONNECT EARTH WIRE

    
    
    1. 

       Remove the bolt to disconnect the earth wire from the engine moving control rod bracket.

57. Click here

    REMOVE ENGINE MOVING CONTROL ROD BRACKET

    
    
    1. 

       Remove the 4 bolts and engine moving control rod bracket.

58. Click here

    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.

       Tip:

       Perform this procedure only when replacement of the engine moving control rod is necessary.

59. Click here

    DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

60. Click here

    DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

    Click here

61. Click here

    REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

62. Click here

    SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

63. Click here

    REMOVE FRONT AXLE SHAFT NUT LH

    Click here

64. Click here

    REMOVE FRONT AXLE SHAFT NUT RH

    Tip:

    Use the same procedure described for the LH side.

65. Click here

    SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

    Click here

66. Click here

    SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

67. Click here

    SEPARATE FRONT SPEED SENSOR LH

    Click here

68. Click here

    SEPARATE FRONT SPEED SENSOR RH

    Tip:

    Use the same procedure described for the LH side.

69. Click here

    SEPARATE TIE ROD ASSEMBLY LH

    Click here

70. Click here

    SEPARATE TIE ROD ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

71. Click here

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

    Click here

72. Click here

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

    Tip:

    Use the same procedure described for the LH side.

73. Click here

    SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

74. Click here

    SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

75. Click here

    REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

76. Click here

    REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

77. Click here

    REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

78. Click here

    REMOVE FLYWHEEL HOUSING UNDER COVER

    
    
    1. 

       Remove the flywheel housing under cover.

79. Click here

    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.

       Table 2. 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.

         Table 3. Text in Illustration

         *1	No. 2 Motor Water Jacket Cover Assembly

    2. 

       Remove the 4 bolts, 2 nuts, frame side rail plate RH and frame side rail plate LH.

       Table 4. Text in Illustration

       *a

       Nut

    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.

80. Click here

    DISCONNECT WIRE HARNESS

    Click here

81. Click here

    REMOVE ENGINE WIRE

    
    

    1. Remove the engine wire from the engine assembly.

82. Click here

    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.

83. Click here

    REMOVE FRONT ENGINE MOUNTING INSULATOR

    
    
    1. 

       Remove the 3 nuts and front engine mounting insulator.

       Tip:

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

84. Click here

    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.

       Tip:

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

85. Click here

    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.

       Tip:

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

86. Click here

    REMOVE ENGINE MOUNTING BRACKET RH

    
    
    1. 

       Remove the 3 bolts and engine mounting bracket RH.

87. Click here

    REMOVE DRIVE SHAFT BEARING BRACKET

    
    
    1. 

       Remove the 3 bolts and drive shaft bearing bracket.

88. Click here

    REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

89. Click here

    REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

    Click here

90. Click here

    REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

    Click here

91. Click here

    REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

92. Click here

    INSTALL ENGINE STAND

    
    

    1. Install the engine assembly to an engine stand.