HYBRID VEHICLE TRANSAXLE REMOVAL

PRECAUTION

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REMOVE REAR FLOOR MAT
1. Remove the rear floor mat.
REMOVE REAR DECK FLOOR BOX
1. Remove the rear deck floor box.
REMOVE BATTERY BOX COVER
1. Disengage the 3 guides and remove the battery box cover.
DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
REMOVE SERVICE PLUG GRIP
CAUTION:
- Wear insulating gloves.
- Remove the service plug grip to interrupt the high voltage circuit at the time of inspection or repair.
- Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
- All the high voltage wiring connectors are colored in orange.
1. Wear insulating gloves and remove the service plug grip after sliding up the lever of the service plug grip as shown in the illustration.
  CAUTION:
  
  Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
  
  After removing the service plug grip, do not touch the high voltage connectors or terminals for 10 minutes.
  Tech Tips
  
  Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.
REMOVE HOOD INSULATOR
1. Using a clip remover, remove the 6 clips and the hood insulator.
REMOVE HOOD SUB-ASSEMBLY
1. Disconnect the 3 clamps and washer hose.
2. Remove the 4 bolts and hood sub-assembly.
ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
REMOVE FRONT WHEEL
REMOVE REAR ENGINE UNDER COVER LH
REMOVE REAR ENGINE UNDER COVER RH
REMOVE ENGINE UNDER COVER
REMOVE NO. 1 ENGINE UNDER COVER
REMOVE CENTER NO. 4 ENGINE UNDER COVER

DRAIN COOLANT (for Engine)

Note

Do not remove the reservoir tank cap and radiator drain cock plug while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Remove the reservoir tank cap.

Text in Illustration
*1	Reservoir Tank Cap	*2	Radiator Drain Cock Plug
*3	Air Release Valve (w/ Air Release Valve)	-	-

Loosen the radiator drain cock plug and drain the coolant.

Tech Tips

Collect the coolant in a container and dispose of it according to the local regulations.

DRAIN COOLANT (for Inverter)
Note
- Do not reuse the drained coolant because it may contain foreign objects.
- Collect the drained coolant and measure its volume to establish a benchmark. When adding coolant, make sure to add more coolant than the measured amount.
1. Remove the reserve tank cap.
  
  CAUTION:
  
  To avoid the danger of being burned, do not remove the reserve tank cap while the coolant for the inverter is still hot.
2. Using a hexagon wrench (10 mm), remove the drain plug indicated in the illustration and drain the coolant.
  
  CAUTION:
  
  Use caution when handling coolant immediately after driving or in summer because it may be hot.
3. Install the plug with a new gasket.
  
  Torque:
  
  39 N*m { 397 kgf*cm, 29 ft.*lbf }
DRAIN HYBRID TRANSAXLE FLUID
1. Text in Illustration
  
  *1 Filler Plug
  
  *2 Drain Plug
  
  Using a 10 mm hexagon socket wrench, remove the filler plug and gasket.
2. Using a 10 mm hexagon socket wrench, remove the drain plug and gasket.
3. Using a 10 mm hexagon socket wrench, install the drain plug and a new gasket.
  
  Torque:
  
  50 N*m { 510 kgf*cm, 37 ft.*lbf }
REMOVE FRONT WIPER ARM HEAD CAP
1. Remove the 2 windshield wiper arm head caps.
REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
1. Remove the nut and the front wiper arm and blade assembly LH.
REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
1. Remove the nut and the front wiper arm and blade assembly RH.
REMOVE HOOD TO COWL TOP SEAL
1. Disengage the 7 clips and remove the hood to cowl top seal.
REMOVE COWL TOP VENTILATOR LOUVER RH
1. Disengage the clip and 11 claws, and remove the cowl top ventilator louver RH.
REMOVE COWL TOP VENTILATOR LOUVER LH
1. Disengage the clip and 6 claws, and remove the cowl top ventilator louver LH.
REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
1. Disconnect the connector.
2. Remove the 2 bolts and the windshield wiper motor and link assembly.
REMOVE COWL BODY MOUNTING REINFORCEMENT LH (for LHD)
1. Remove the 3 bolts and cowl body mounting reinforcement LH.
REMOVE COWL BODY MOUNTING REINFORCEMENT LH (for RHD)
1. Remove the 3 bolts and cowl body mounting reinforcement LH.

Text in Illustration
*1	Filler Plug
*2	Drain Plug

REMOVE OUTER COWL TOP PANEL (for LHD)

Text in Illustration
*1	No. 1 Heater Air Duct Splash Shield Seal
*2	Water Guard Plate RH

Disengage each claw of the No. 1 heater air duct splash shield seal and water guard plate RH, and bend them.

Disengage the clamp and separate the wire harness.
Remove the 8 bolts, nut and outer cowl top panel.

REMOVE OUTER COWL TOP PANEL (for RHD)

Text in Illustration
*1	Water Guard Plate RH
*2	No. 1 Heater Air Duct Splash Shield Seal

Disengage each claw of the water guard plate RH and No. 1 heater air duct splash shield seal, and bend them.

Disengage the clamp and separate the wire harness.
Remove the 8 bolts, nut and outer cowl top panel.

REMOVE NO. 2 CYLINDER HEAD COVER
1. Remove the 3 clips and No. 2 cylinder head cover.
  Note
  
  Attempting to disengage both front and rear clips at the same time may cause the cover to break.
  
  Pull the cover straight up to remove. Attempting to pull the cover forward may cause it to break.
REMOVE AIR CLEANER CAP SUB-ASSEMBLY
1. Disconnect the air flow meter connector.
2. Disconnect the 2 clamps and hose band, and remove the air cleaner cap sub-assembly.
3. Remove the air cleaner filter element.
REMOVE INLET AIR CLEANER ASSEMBLY
1. Separate the water by-pass hose from the inlet air cleaner assembly.
2. Remove the 3 bolts and inlet air cleaner assembly.
REMOVE AIR CLEANER CASE
1. Separate the No. 4 water by-pass hose from the air cleaner case.
2. Remove the 3 bolts and air cleaner case.
REMOVE NO. 1 INVERTER BRACKET
1. Remove the 3 bolts and No. 1 inverter bracket.
DISCONNECT ENGINE ROOM MAIN WIRE
1. Raise the lock lever and disconnect the inverter with converter connector.
2. Disconnect the engine wire from the engine room main wire.
3. Remove the bolt.
4. Remove the bolt, clamp and clip, and disconnect the engine room main wire.
REMOVE INVERTER TERMINAL COVER
CAUTION:

Wear insulating gloves.
1. Remove the 9 bolts and inverter terminal cover.
  
  Note
  
  Make sure to pull the inverter terminal cover straight up, as a connector is connected to the bottom of the cover.
CHECK TERMINAL VOLTAGE
CAUTION:

Wear insulating gloves.

Note

Do not allow any foreign objects or water to enter the inverter with converter assembly.
1. Using a voltmeter, measure the voltage between the terminals of the 2 phase connectors.
  
  Standard voltage
  
  0 V
  
  Tech Tips
  
  Use measuring range of DC 750 V or more on the voltmeter.
DISCONNECT FRAME WIRE
CAUTION:

Wear insulating gloves.
Note
- Insulate the removed terminals with insulating tape.
- Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.
1. Remove the 4 bolts, and disconnect the frame wire (high voltage cables of the hybrid battery) from the inverter with converter assembly.
2. Disconnect the harness clamp.
DISCONNECT HIGH VOLTAGE CABLE OF FRONT TRANSAXLE
CAUTION:

Wear insulating gloves.
Note
- Insulate the removed terminals with insulating tape.
- Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.
1. Remove the 5 bolts, and disconnect the high voltage cables of the generator (MG1) from the inverter with converter assembly.
2. Turn back the wire harness cover and release the cable.
3. Remove the 5 bolts, and disconnect the high voltage cables of the motor (MG2) from the inverter with converter assembly.
4. Disconnect the harness clamp.
DISCONNECT NO. 2 ENGINE WIRE
CAUTION:

Wear insulating gloves.
Note
- Insulate the removed terminals with insulating tape.
- Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.
1. Remove the 4 bolts, and disconnect the No. 2 engine wire (high voltage cables for the air conditioning compressor) from the inverter with converter assembly.
2. Disconnect the harness clamp.
INSTALL INVERTER TERMINAL COVER
1. Temporarily install the inverter terminal cover with the 9 bolts to prevent any foreign objects or water from entering the inverter with converter assembly.
DISCONNECT NO. 2 ENGINE ROOM WIRE
1. Remove the relay block cover.
2. Release the 2 clamps, and remove the No. 1 relay block cover.
3. Remove the bolt from the No. 2 engine room wire.
4. Release the 2 claws, and disconnect the No. 2 engine room wire.
5. Connect the No. 2 engine room wire to the protector.
DISCONNECT WATER HOSE
1. Text in Illustration
  
  *1 Retainer
  
  Release the retainer and disconnect the water hose from the inverter with converter assembly.
2. Text in Illustration
  
  *1 Retainer
  
  Release the retainer and disconnect the water hose from the inverter with converter assembly.
3. Disconnect the coolant hose from the inverter with converter assembly. Put a piece of cloth in the pipe and in the disconnected hose or cover the pipe and hose with plastic bags as shown in the illustration, so that foreign matter doesn't stick to the union or the inside of the connector and to prevent coolant from spilling near the inverter with converter assembly.
REMOVE INVERTER WITH CONVERTER ASSEMBLY
CAUTION:

Wear insulating gloves.
1. Remove the 3 bolts and inverter with converter assembly.
  Note
  
  Since the inverter with converter assembly is very heavy, 2 people are needed to remove the inverter with converter assembly. When removing the inverter with converter assembly, do not damage the parts around it.
  
  To prevent damage, do not hold the inverter with converter assembly by the connectors.
  
  To prevent damage due to static electricity, do not touch the terminals of the disconnected connectors.
2. Even after the coolant is drained, coolant remains in the inverter due to its internal structure. Therefore, seal or cover the pipes when removing the inverter so that coolant does not spill out.
REMOVE INVERTER RESERVE TANK ASSEMBLY
1. Remove the 2 bolts and inverter reserve tank assembly.
REMOVE INVERTER TRAY BRACKET
1. Separate the 2 clamps.
2. Remove the 5 bolts and inverter tray bracket.
DISCONNECT NO. 1 RADIATOR HOSE
1. Disconnect the No. 1 radiator hose from the radiator pipe assembly.
DISCONNECT NO. 4 WATER BY-PASS HOSE
1. Disconnect the No. 4 water by-pass hose from the radiator pipe assembly.
REMOVE RADIATOR PIPE
1. Separate the No. 3 radiator hose from the cylinder head.
2. Remove the 2 bolts and radiator pipe.
DISCONNECT NO. 3 INVERTER COOLING HOSE
1. Disconnect the No. 3 inverter cooling hose from the hybrid transaxle assembly.
DISCONNECT NO. 5 INVERTER COOLING HOSE
1. Disconnect the No. 5 inverter cooling hose from the hybrid transaxle assembly.
DISCONNECT WIRE HARNESS
1. Disconnect the 2 clamps.
2. Pull up the lever and disconnect the connector of the ECM.
3. Remove the 2 connectors and 2 clamps from the engine room junction block and disconnect the wire harness.
4. Disconnect the 2 clamps.
5. Text in Illustration
  
  *1 Green-colored Lock
  
  Release the green-colored lock and disconnect the connector as shown in the illustration.
  
  CAUTION:
  
  Wear insulated gloves when performing the procedure.
  
  Note
  
  Insulate the connector by sealing it with tape.
6. Disconnect the 2 clamps and wire harness.
7. Remove the 2 bolts and disconnect the 6 connectors and 12 wire harness clamps.
SECURE STEERING WHEEL
1. Secure the steering wheel with the seat belt in order to prevent rotation.
  
  Tech Tips
  
  This operation is useful to prevent damage to the spiral cable.
REMOVE COLUMN HOLE COVER SILENCER SHEET
1. Turn back the floor carpet, and remove the 2 clips and column hole cover silencer sheet.
SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
1. Remove the bolt.
  
  Note
  
  Do not separate the No. 2 steering intermediate shaft assembly from the steering intermediate shaft.
2. Text in Illustration
  
  *1 Matchmark
  
  Put matchmarks on the No. 2 steering intermediate shaft assembly and the steering intermediate shaft.
3. Separate the No. 2 steering intermediate shaft assembly from the steering intermediate shaft.

Standard voltage
0 V

Text in Illustration
*1	Retainer

Text in Illustration
*1	Retainer

Text in Illustration
*1	Green-colored Lock

Text in Illustration
*1	Matchmark

SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

Text in Illustration
*1	Clip A
*2	Clip B
*a	Lip

Remove clip A, detach clip B from the body and disconnect the No. 1 steering column hole cover sub-assembly.

Note

Do not damage clips A and B.

REMOVE NO. 2 ENGINE UNDER COVER
1. Remove the 4 clips and No. 2 engine under cover.
REMOVE FRONT CENTER FLOOR BRACE
1. Remove the 4 bolts and front center floor brace.
REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/ Exhaust Heat Recirculation System)
1. Disconnect the 3 clamps and oxygen sensor connector.
2. Disconnect the 2 heater water hoses.
3. Remove the 4 bolts and 4 compression springs.
4. Remove the front exhaust pipe assembly from the 3 exhaust pipe supports.
5. Remove the 2 gaskets from the front exhaust pipe assembly and exhaust manifold.
REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/o Exhaust Heat Recirculation System)
1. Remove the 4 bolts and 4 compression springs.
2. Remove the front exhaust pipe assembly from the 3 exhaust pipe supports.
3. Remove the 2 gaskets from the front exhaust pipe assembly and exhaust manifold.
REMOVE FRONT AXLE SHAFT NUT LH
1. Using SST and a hammer, unstake the staked part of the front axle shaft nut.
  
  SST
  
  09930-00010
  
  Note
  
  Loosen the staked part of the front axle shaft nut completely, otherwise the threads on the drive shaft may be damaged.
2. While applying the brakes, remove the front axle shaft nut.
REMOVE FRONT AXLE SHAFT NUT RH

Tech Tips

Perform the same procedure as for the LH side.
SEPARATE FRONT SPEED SENSOR LH
1. Remove the bolt and clamp, and separate the front speed sensor.
  
  Note
  
  Be sure to separate the front speed sensor from the front shock absorber with coil spring completely.
2. Remove the bolt and separate the front speed sensor from the steering knuckle.
  Note
  
  Prevent foreign matter from attaching to the sensor tip.
  
  Be careful not to damage the front speed sensor.
  
  Clean the installation hole and the surface for the speed sensor every time the speed sensor is removed.
SEPARATE FRONT SPEED SENSOR RH

Tech Tips

Perform the same procedure as for the LH side.

SEPARATE TIE ROD END SUB-ASSEMBLY LH

Remove the cotter pin and nut.
Install SST to the tie rod end.

SST

09960-20010 ( 09961-02060 )

Note

Make sure that the upper ends of the tie rod end and SST are aligned.

Using SST, separate the tie rod end from the steering knuckle.

Text in Illustration
*1	Nut	-	-
*a	Tighten the string without leaving any slack.	*b	Grease Application Area
*c	Place the wrench here.	-	-

SST: 09960-20010 ( 09961-02010 )

CAUTION:

Apply grease to the bolt threads and the tip of SST.

Note

Be sure to tighten the string firmly to secure SST to the steering knuckle to prevent SST from falling off.
Install SST with the center nut so that A and B shown in the illustration are parallel. Otherwise, the dust cover may be damaged.
Be sure to place the wrench on the part indicated in the illustration.
Do not damage the front disc brake dust cover.
Do not damage the ball joint dust cover.
Do not damage the steering knuckle.

SEPARATE TIE ROD END SUB-ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
1. Remove the nut and separate the front stabilizer link assembly from the front shock absorber with coil spring.
  
  Tech Tips
  
  If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud bolt.
SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
SEPARATE FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY LH
1. Remove the bolt and 2 nuts.
2. Separate the front No. 1 lower suspension arm sub-assembly from the front lower ball joint.
SEPARATE FRONT NO. 1 LOWER SUSPENSION ARM SUB-ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
SEPARATE FRONT AXLE ASSEMBLY LH
1. Text in Illustration
  
  *a Matchmark
  
  Put matchmarks on the front drive shaft assembly LH and axle hub.
  
  Note
  
  Do not punch the marks.
2. Using a plastic-faced hammer, disconnect the front axle assembly LH.
  Note
  - Be careful not to damage the outboard joint boot and deflector.
  - Do not excessively push out the drive shaft from the axle assembly.
REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
1. Using SST, remove the front drive shaft assembly LH.
  
  SST
  
  09520-00031
  
  09520-01010
  Note
  
  Be careful not to damage the transaxle case oil seal, inboard joint boot and drive shaft dust cover.
  
  Be careful not to drop the drive shaft assembly LH.
SEPARATE FRONT AXLE ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

Tech Tips

Perform the same procedure as for the LH side.
REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH
1. Using a screwdriver, remove the front drive shaft hole snap ring.
REMOVE FRONT DRIVE SHAFT HOLE SNAP RING RH

Tech Tips

Perform the same procedure as for the LH side.

Text in Illustration
*a	Matchmark

INSTALL ENGINE HANGERS

Install the 2 engine hangers with the 2 bolts.

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

Part Name	Part No.
No. 1 engine hanger	12281-37021
No. 2 engine hanger	12282-37011
Bolt	91552-81050

Attach a sling device to the engine hangers and a chain block.

REMOVE STARTER HOLE INSULATOR
1. Remove the 2 bolts and starter hole insulator.
REMOVE FLYWHEEL HOUSING SIDE COVER
1. Remove the flywheel housing side cover.
REMOVE FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT
1. Remove the 2 bolts and front engine mounting bracket lower reinforcement.
REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH
1. Remove the 4 bolts and front suspension member reinforcement LH.
REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

Tech Tips

Perform the same procedure as for the LH side.
REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH
1. Remove the 3 bolts, clip and front suspension member rear brace LH.
REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

Tech Tips

Perform the same procedure as for the LH side.
REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
1. Remove the 2 bolts and 2 wire harness clamp brackets from the front suspension crossmember sub-assembly.
2. Remove the 2 bolts and 2 nuts, and separate the front suspension crossmember sub-assembly from the rear engine mounting insulator.
3. Using a jack, support the front suspension crossmember sub-assembly.
4. Remove the 2 bolts and front suspension crossmember sub-assembly.
REMOVE REAR ENGINE MOUNTING INSULATOR
1. Remove the through bolt, and separate the rear engine mounting insulator.
  
  Tech Tips
  
  Perform this procedure only when replacement of the engine mounting insulator is necessary.
SUPPORT HYBRID VEHICLE TRANSAXLE ASSEMBLY
1. Support the hybrid vehicle transaxle assembly with a transmission jack.
REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY
1. Remove the bolt and nut.
2. Remove the 4 bolts and front crossmember sub-assembly.
REMOVE FRONT ENGINE MOUNTING INSULATOR
1. Remove the 2 bolts and front engine mounting insulator.
REMOVE ENGINE MOUNTING BRACKET LH
1. Remove the bolt and nut, and separate the engine mounting insulator LH.
2. Remove the 3 bolts and engine mounting bracket LH.
REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY
1. Remove the 7 bolts and hybrid vehicle transaxle assembly.
  
  Note
  
  To avoid damage to the knock pins, do not pry between the hybrid transaxle and the engine.
REMOVE FRONT ENGINE MOUNTING BRACKET
1. Remove the 3 bolts and front engine mounting bracket.
REMOVE REAR ENGINE MOUNTING BRACKET
1. Remove the 4 bolts and rear engine mounting bracket.
REMOVE WIRE HARNESS CLAMP BRACKET
1. Remove the 2 bolts and 2 wire harness clamp brackets.
REMOVE MOTOR CABLE BRACKET
1. Remove the bolt and motor cable bracket.