ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

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.

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 ignition 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. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  3. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  4. REMOVE SERVICE PLUG GRIP

    Click here

  5. REMOVE ENGINE UNDER COVER LH

  6. REMOVE ENGINE UNDER COVER RH

  7. DRAIN ENGINE OIL

    Click here

  8. DRAIN COOLANT (for Engine)

    Click here

  9. DRAIN COOLANT (for Inverter)

    Click here

  10. DRAIN HYBRID TRANSAXLE FLUID

    Click here

  11. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  12. REMOVE FRONT NO. 1 VENTILATOR SEAL (for LHD)

    Click here

  13. REMOVE FRONT NO. 1 VENTILATOR SEAL (for RHD)

    Click here

  14. REMOVE FRONT AIR SHUTTER SEAL RH (for LHD)

    Click here

  15. REMOVE FRONT AIR SHUTTER SEAL RH (for RHD)

    Click here

  16. REMOVE INNER COWL TOP TO COWL BRACE (for LHD)

    Click here

  17. REMOVE INNER COWL TOP TO COWL BRACE (for RHD)

    Click here

  18. REMOVE OUTER COWL TOP PANEL (for LHD)

    Click here

  19. REMOVE OUTER COWL TOP PANEL (for RHD)

    Click here

  20. REMOVE NO. 2 CYLINDER HEAD COVER (w/ No. 2 Cylinder Head Cover)

    Click here

  21. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

  22. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    B00414L

    1. Disconnect the hose clamp and ventilation hose.

    2. B004117

      Disconnect the wire harness clamp and purge VSV connector.

    3. Disconnect the No. 1 fuel vapor feed hose and No. 2 fuel vapor feed hose.

    4. B0040WS

      Disconnect the wire harness clamp and mass air flow meter connector.

    5. Release the 2 clamps.

    6. B0040U9

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

  23. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  24. REMOVE INVERTER BRACKET ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. B004159

      Remove the bolt and separate the motor cable protector.

    2. B0040V5

      Disconnect the 2 wire harness clamps.

    3. B00414B

      Remove the 2 bolts and separate the inverter reservoir tank assembly.

    4. B00415Q

      Remove the bolt and disconnect the ground wire.

    5. B004163

      Remove the 4 bolts and inverter bracket assembly.

  25. DISCONNECT NO. 1 RADIATOR HOSE


    1. B00412C

      Disconnect the No. 1 radiator hose from the engine assembly.

  26. DISCONNECT NO. 2 RADIATOR HOSE


    1. B00414N

      Disconnect the No. 2 radiator hose from the engine assembly.

  27. DISCONNECT HEATER WATER HOSE


    1. B0040Z6

      Disconnect the 2 heater water hoses from the engine assembly.

  28. SEPARATE NO. 1 FUEL VAPOR FEED HOSE


    1. B00412N

      Disconnect the 2 hose clamps and separate the No. 1 fuel vapor feed hose.

  29. REMOVE EFI FUEL PIPE CLAMP

    Click here

  30. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  31. DISCONNECT ENGINE WIRE (for LHD)


    1. B0040WR

      Push the lock on the lever, then raise the lever, and disconnect the ECM connector.

      Note

      If there is any foreign matter such as mud or water on a connector, clean the connector.

    2. Disconnect the 2 wire harness clamps.

    3. B0040WY

      Disconnect the 2 connectors and 2 wire harness clamps.

    4. Using a screwdriver, disengage the claw and disconnect the engine wire from the engine room relay block and junction block assembly.

    5. B0040WJ

      Disconnect the engine wire from the engine room main wire.

    6. Disconnect the wire harness clamp.

  32. DISCONNECT ENGINE WIRE (for RHD)


    1. B004114

      Push the lock on the lever, then raise the lever, and disconnect the ECM connector.

      Note

      If there is any foreign matter such as mud or water on a connector, clean the connector.

    2. B0040WY

      Disconnect the 2 connectors and 2 wire harness clamps.

    3. Using a screwdriver, disengage the claw and disconnect the engine wire from the engine room relay block and junction block assembly.

    4. B0040WJ

      Disconnect the engine wire from the engine room main wire.

    5. Disconnect the wire harness clamp.

  33. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  34. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  35. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  36. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

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

    Click here

  38. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  39. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  40. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  41. REMOVE FRONT FLOOR CENTER BRACE

    Click here

  42. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  43. SEPARATE NO. 2 ENGINE ROOM RELAY BLOCK AND NO. 2 JUNCTION BLOCK ASSEMBLY

    Click here

  44. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  45. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. B0040XT

      Remove the flywheel housing under cover.

  46. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. B00415IE03
      Text in Illustration
      *1 No. 2 Oil Pan Sub-assembly
      *2 Drain Plug
      *3 Rear Cover Plug
      B00412T Attachment Installation Position

      Place height adjustment attachments or plate lift attachments in the positions as shown in the illustration and set an engine lifter underneath the engine assembly with transaxle and crossmember.

      Note


      • Place the height adjustment attachment and plate lift attachment so that the engine assembly with transaxle is level.

      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.

      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.

      • Do not place any attachments onto the drain plug and rear cover plug of the hybrid vehicle transaxle assembly.

    2. B0040W8

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

    3. B0040UF

      Remove the bolt and nut, and separate the engine mounting insulator LH from the engine mounting bracket LH.

    4. B0040VW

      Remove the 6 bolts, operate the engine lifter and slowly remove the engine assembly with transaxle and front suspension crossmember sub-assembly from the vehicle.

      Note

      Make sure that the engine is clear of all wiring and hoses.

  47. INSTALL NO. 1 ENGINE HANGER


    1. B004104

      Install the 2 No. 1 engine hangers with 2 new bolts.

      Torque:
      44 N*m  { 448 kgf*cm, 32 ft.*lbf }
      Part Name Part No.
      No. 1 engine hanger 12281-21090
      Bolt 91672-81025

  48. FIX ENGINE ASSEMBLY WITH TRANSAXLE


    1. Using a chain block and engine sling device, hold the engine assembly with transaxle.

      Note

      Make sure that the sling angle is correct to prevent the engine assembly and engine hangers from being damaged or deformed.

    2. B00415EE02
      Text in Illustration
      *1 No. 2 Oil Pan Sub-assembly
      *2 Drain Plug
      *3 Rear Cover Plug
      B00412T Attachment Installation Position

      To enable removal of the engine assembly, adjust the positions of the height adjustment attachment and plate lift attachment and set them in place.

      Note


      • Place the height adjustment attachment and plate lift attachment so that the engine assembly with transaxle is level.

      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.

      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.

      • Do not place any attachments onto the drain plug and rear cover plug of the hybrid vehicle transaxle assembly.

    3. B0040UI

      Using a rope or belt, secure the engine assembly with transaxle to the engine lifter.

      Note


      • Set the engine assembly with transaxle so that it is level.

      • Do not tighten the rope or belt with a tightening mechanism or any more than is necessary.

  49. REMOVE ENGINE ASSEMBLY


    1. B0040YQ

      Disconnect the 4 clamps and No. 2 engine wire.

    2. Remove the 3 bolts and disconnect the 4 connectors, 7 clamps and wire harness from the hybrid vehicle transaxle assembly.

      B00415K
    3. B004135E03
      Text in Illustration
      *1 Wire Harness Clamp Bracket
      *2 Transmission Control Cable Clamp

      Remove the 3 bolts, 2 wire harness clamp brackets and transmission control cable clamp from the hybrid vehicle transaxle assembly.

    4. B00416K

      Remove the bolt, nut and drive shaft heat insulator sub-assembly from the engine and drive shaft heat insulator bracket.

    5. B00412M

      Disconnect the clamp from the drive shaft heat insulator bracket.

    6. Remove the 2 bolts and drive shaft heat insulator bracket from the engine.

    7. B004132

      Remove the 2 bolts and starter hole heat insulator from the engine.

    8. B00410R

      Disengage the claw and remove the flywheel housing side cover from the engine.

    9. B00414K

      Remove the 6 bolts and the engine assembly from the hybrid vehicle transaxle assembly.

      Note


      • To avoid damage to the knock pins, do not pry between the hybrid vehicle transaxle assembly and the engine.

      • To prevent the splines of the damper from becoming misaligned, do not allow the transaxle to hit the damper during transaxle removal and installation.

  50. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY


    1. Gently place the engine assembly onto wood blocks or equivalent.

      Note


      • Set the engine assembly so that it is level.

      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.

      • This step should be done while hanging the engine assembly using the sling device and chain block.

    2. Remove the transmission input damper assembly Click here.

  51. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. Gently place the engine assembly onto wood blocks or equivalent.

      Note


      • Set the engine assembly so that it is level.

      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.

      • This step should be done while hanging the engine assembly using the sling device and chain block.

    2. Remove the flywheel sub-assembly Click here.

  52. 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. B00411L

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

  53. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B004169

      Disconnect the wire harness clamp.

    2. Remove the 5 bolts and engine mounting insulator LH.

  54. INSTALL ENGINE STAND


    1. Using a sling device and chain block, install the engine stand to the engine assembly.

      Note


      • Make sure that the sling angle is correct to prevent the engine assembly and engine hangers from being damaged or deformed.

      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.

  55. DISCONNECT ENGINE WIRE


    1. Disconnect all of the clamps and connectors and remove the engine wire from the engine assembly.

  56. REMOVE NO. 1 ENGINE HANGER


    1. Remove the 2 bolts and 2 No. 1 engine hangers.