HYBRID VEHICLE TRANSAXLE REMOVAL


  1. PRECAUTION

    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. REMOVE REAR NO. 2 FLOOR BOARD


    1. Remove the rear No. 2 floor board.

  3. REMOVE REAR DECK FLOOR BOX


    1. Remove the rear deck floor box.

  4. REMOVE REAR NO. 3 FLOOR BOARD


    1. Remove the rear No. 3 floor board.

  5. REMOVE DECK FLOOR BOX RH


    1. A003Z5J

      Remove the clip.

    2. Disengage the 6 guides and remove the deck floor box RH.

  6. REMOVE REAR FLOOR BOARD UPPER NO. 3 PLATE


    1. A003VKN

      Disengage the 4 claws and 2 guides, and remove the rear floor board upper No. 3 plate.

  7. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  8. 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.

    • High voltage wiring connectors are orange.


    1. Wear insulated gloves and remove the service plug grip after sliding up the lever of the service plug grip as shown in the illustration.

      A003XIK

      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.

  9. REMOVE HOOD SUB-ASSEMBLY


    1. A003ZUO

      Disconnect the clamp and washer hose.

    2. Remove the 4 bolts and hood sub-assembly.

  10. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  11. REMOVE FRONT WHEEL

  12. REMOVE REAR ENGINE UNDER COVER LH

  13. REMOVE REAR ENGINE UNDER COVER RH

  14. REMOVE FRONT LOWER BUMPER ABSORBER

  15. REMOVE NO. 1 ENGINE UNDER COVER

  16. DRAIN COOLANT (for Engine)

    for 2ZR-FXE Click here

    for 5ZR-FXE Click here

  17. 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. A003Z26

      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 }

  18. DRAIN HYBRID TRANSAXLE FLUID


    1. A003XN9E01
      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 }

  19. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  20. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    1. A003VJD

      Disengage the 2 claws and remove the No. 1 heater air duct splash shield seal.

  21. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. A003Z14

      Disengage the 2 claws and remove the No. 1 heater air duct splash shield seal.

  22. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)


    1. A003Y4M

      Disengage the claw and guide, and remove the No. 2 heater air duct splash shield seal.

  23. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)


    1. A003WN3

      Disengage the claw and guide, and remove the No. 2 heater air duct splash shield seal.

  24. REMOVE COWL BODY MOUNTING REINFORCEMENT LH (for LHD)


    1. A003WMR

      Remove the 2 bolts and cowl body mounting reinforcement LH.

  25. REMOVE COWL BODY MOUNTING REINFORCEMENT RH (for RHD)


    1. A003YWK

      Remove the 2 bolts and cowl body mounting reinforcement RH.

  26. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)


    1. A003W0I

      Disengage the clamp and separate the wire harness.

    2. A003WSZ

      w/ Wiper Deicer:

      Disengage the 3 clamps, disconnect the connector and separate the wire harness.

    3. A003YRF

      Remove the 9 bolts and outer cowl top panel sub-assembly.

  27. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)


    1. A003X05

      Disengage the clamp and separate the wire harness.

    2. A003X62

      w/ Wiper Deicer:

      Disengage the 3 clamps, disconnect the connector and separate the wire harness.

    3. A003ZGV

      Remove the 9 bolts and outer cowl top panel sub-assembly.

  28. REMOVE SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper)


    1. A003VPIE01
      Text in Illustration
      *a LH Side
      *b RH Side

      Remove the 2 nuts and the suspension tower damper from the vehicle.

  29. REMOVE NO. 2 CYLINDER HEAD COVER (for 2ZR-FXE)


    1. A003WMME01

      Remove the 3 clips and No. 2 cylinder head cover.

      Note


      • Disengage the clips in the order shown in the illustration.

      • When disengaging clip 3, hold the end of the cover behind clip 3 and lift the cover straight up.

      • 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 or pull it up by holding the left and right ends may cause the cover to break.

  30. REMOVE NO. 2 CYLINDER HEAD COVER (for 5ZR-FXE)


    1. A003WMME01

      Remove the 3 clips and No. 2 cylinder head cover.

      Note


      • Disengage the clips in the order shown in the illustration.

      • When disengaging clip 3, hold the end of the cover behind clip 3 and lift the cover straight up.

      • 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 or pull it up by holding the left and right ends may cause the cover to break.

  31. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FXE)


    1. A003VQ1

      Disconnect the air flow meter connector.

    2. Separate the water by-pass hose from the air cleaner cap sub-assembly.

    3. Disconnect the 2 clamps and hose band, and remove the air cleaner cap sub-assembly.

    4. Remove the air cleaner filter element sub-assembly.

  32. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 5ZR-FXE)


    1. A003ZFN

      Disconnect the connector and wire harness clamp.

    2. A003XA5

      Disconnect the water hose from the clamp.

    3. Disengage the 2 clamps and remove the air cleaner cap sub-assembly.

    4. Loosen the hose clamp and disconnect the air cleaner hose assembly.

  33. REMOVE INLET AIR CLEANER (for 2ZR-FXE)


    1. A003YDS

      Separate the water by-pass hose from the inlet air cleaner.

    2. Separate the wire harness clamp from the inlet air cleaner.

    3. Remove the 2 bolts, 2 clips and inlet air cleaner.

  34. REMOVE INLET AIR CLEANER (for 5ZR-FXE)


    1. A003YDS

      Separate the water by-pass hose from the inlet air cleaner.

    2. Separate the wire harness clamp from the inlet air cleaner.

    3. Remove the 2 bolts, 2 clips and inlet air cleaner.

  35. REMOVE AIR CLEANER CASE (for 2ZR-FXE)


    1. A003VGW

      Separate the No. 4 water by-pass hose from the air cleaner case.

    2. Disconnect the wire harness clamp from the air cleaner case.

    3. Remove the 2 bolts and air cleaner case.

  36. REMOVE AIR CLEANER CASE (for 5ZR-FXE)


    1. A003VGW

      Separate the No. 4 water by-pass hose from the air cleaner case.

    2. Disconnect the wire harness clamp from the air cleaner case.

    3. Remove the 2 bolts and air cleaner case.

  37. REMOVE AIR CLEANER HOSE ASSEMBLY (for 2ZR-FXE)


    1. A003WXN

      Disconnect the ventilation hose from the cylinder head cover sub-assembly.

    2. Loosen the hose clamp and remove the air cleaner hose assembly from the throttle body assembly.

  38. REMOVE AIR CLEANER HOSE ASSEMBLY (for 5ZR-FXE)


    1. A003WXN

      Disconnect the ventilation hose from the cylinder head cover sub-assembly.

    2. Loosen the hose clamp and remove the air cleaner hose assembly from the throttle body assembly.

  39. REMOVE INVERTER COVER ASSEMBLY LH (w/ Cover)


    1. A003WP0

      Remove the 2 clips

    2. Disengage the claw and remove the inverter cover assembly LH.

  40. REMOVE RADIATOR SUPPORT OPENING COVER


    1. A003ZJQ

      Remove the 9 clips and radiator support opening cover (for 9 Clip Type).

    2. A003XV0

      Remove the 7 clips and radiator support opening cover (for 7 Clip Type).

  41. REMOVE NO. 1 INVERTER BRACKET


    1. A003YRX

      Remove the 3 bolts and No. 1 inverter bracket.

  42. DISCONNECT ENGINE ROOM MAIN WIRE


    1. A003YY7

      Raise the lock lever and disconnect the inverter with converter connector.

    2. A003WA0

      Disconnect the engine wire from the engine room main wire.

    3. A003VAV

      Remove the bolt.

    4. A003ZRT

      Remove the bolt, clamp and clip, and disconnect the engine room main wire.

  43. REMOVE INVERTER COVER

    CAUTION:

    Wear insulating gloves.


    1. A003WQ2

      Remove the 9 bolts and inverter cover.

      Note

      Make sure to pull the inverter cover straight up, as a connector is connected to the bottom of the cover.

  44. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulating gloves.

    Note

    Do not allow any foreign objects or water to enter the inverter with converter assembly.


    1. A003W23

      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.

  45. DISCONNECT FRAME WIRE

    CAUTION:

    Wear insulating gloves.

    Note


    • Insulate the disconnected 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. A003V7O

      Disconnect the 2 harness clamps.

    2. A003WVC

      Remove the 4 bolts, and disconnect the frame wire (high voltage cables of the hybrid battery) from the inverter with converter assembly.

  46. DISCONNECT GENERATOR CABLE

    CAUTION:

    Wear insulating gloves.

    Note


    • Insulate the disconnected 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. A003Y4Z

      Turn back the wire harness cover and release the cable.

    2. A003ZEQ

      Remove the 5 bolts, and disconnect the high voltage cables of the generator cable (MG1) from the inverter with converter assembly.

  47. DISCONNECT MOTOR CABLE

    CAUTION:

    Wear insulating gloves.

    Note


    • Insulate the disconnected 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. A003YEB

      Disconnect the harness clamp.

    2. A003VLR

      Remove the 5 bolts, and disconnect the high voltage cables of the motor cable (MG2) from the inverter with converter assembly.

  48. DISCONNECT NO. 2 ENGINE WIRE

    CAUTION:

    Wear insulating gloves.

    Note


    • Insulate the disconnected 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. A003ZM2

      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. A003WOR

      Disconnect the harness clamp.

  49. INSTALL INVERTER COVER


    1. A003WQ2

      Temporarily install the inverter cover with the 9 bolts to prevent any foreign objects or water from entering the inverter with converter assembly.

  50. DISCONNECT NO. 2 ENGINE ROOM WIRE


    1. Remove the relay block cover.

    2. A003Y00

      Release the 2 clamps, and remove the No. 1 relay block cover.

    3. A003Z58

      Remove the bolt from the No. 2 engine room wire.

    4. Release the 2 claws, and disconnect the No. 2 engine room wire.

    5. A003Z1U

      Connect the No. 2 engine room wire to the protector.

  51. DISCONNECT WATER HOSE


    1. A003YYGE01
      Text in Illustration
      *1 Retainer

      Release the retainer and disconnect the water hose from the inverter with converter assembly.

    2. A003ZGQE01
      Text in Illustration
      *1 Retainer

      Release the retainer and disconnect the water hose from the inverter with converter assembly.

    3. A003V32

      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.

  52. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulating gloves.


    1. A003WZ0

      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. A003XYA

      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.

  53. REMOVE INVERTER RESERVE TANK ASSEMBLY (for 2ZR-FXE)


    1. A003V8F

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

  54. REMOVE INVERTER RESERVE TANK ASSEMBLY (for 5ZR-FXE)


    1. A003V8F

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

  55. REMOVE INVERTER TRAY BRACKET (for 2ZR-FXE)


    1. A003XZQ

      Separate the 2 clamps.

    2. Remove the 5 bolts and inverter tray bracket.

  56. REMOVE INVERTER TRAY BRACKET (for 5ZR-FXE)


    1. A003XZQ

      Separate the 2 clamps.

    2. Remove the 5 bolts and inverter tray bracket.

  57. DISCONNECT NO. 1 RADIATOR HOSE (for 2ZR-FXE)


    1. A003ZSK

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

  58. DISCONNECT NO. 1 RADIATOR HOSE (for 5ZR-FXE)


    1. A003ZSK

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

  59. DISCONNECT NO. 4 WATER BY-PASS HOSE (for 2ZR-FXE)


    1. A003WU3

      Disconnect the No. 4 water by-pass hose from the radiator pipe assembly.

  60. DISCONNECT NO. 4 WATER BY-PASS HOSE (for 5ZR-FXE)


    1. A003WU3

      Disconnect the No. 4 water by-pass hose from the radiator pipe assembly.

  61. REMOVE RADIATOR PIPE (for 2ZR-FXE)


    1. A003WOX

      Separate the No. 3 radiator hose from the cylinder head.

    2. Remove the 2 bolts and radiator pipe.

  62. REMOVE RADIATOR PIPE (for 5ZR-FXE)


    1. A003WOX

      Separate the No. 3 radiator hose from the cylinder head.

    2. Remove the 2 bolts and radiator pipe.

  63. DISCONNECT NO. 3 INVERTER COOLING HOSE (for 2ZR-FXE)


    1. A003ZUCE01
      Text in Illustration
      *1 No. 3 Inverter Cooling Hose
      *2 No. 5 Inverter Cooling Hose

      Disconnect the No. 3 inverter cooling hose from the hybrid transaxle assembly.

  64. DISCONNECT NO. 3 INVERTER COOLING HOSE (for 5ZR-FXE)


    1. A003ZUCE01
      Text in Illustration
      *1 No. 3 Inverter Cooling Hose
      *2 No. 5 Inverter Cooling Hose

      Disconnect the No. 3 inverter cooling hose from the hybrid transaxle assembly.

  65. DISCONNECT NO. 5 INVERTER COOLING HOSE (for 2ZR-FXE)


    1. Disconnect the No. 5 inverter cooling hose from the hybrid transaxle assembly.

  66. DISCONNECT NO. 5 INVERTER COOLING HOSE (for 5ZR-FXE)


    1. Disconnect the No. 5 inverter cooling hose from the hybrid transaxle assembly.

  67. DISCONNECT WIRE HARNESS


    1. A003VAX

      Disconnect the 2 clamps.

    2. Pull up the lever and disconnect the connector of the ECM.

    3. A003YMYE01

      Disconnect the 2 connectors from the engine room junction block.

    4. Using a screwdriver, disconnect the 2 claws and wire harness from the engine room junction block.

      Text in Illustration
      *1 Protective Tape

      Tech Tips

      Tape the screwdriver tip before use.

    5. A003Z5V

      Disconnect the 2 clamps.

    6. A003XLCE02
      Text in Illustration
      *a 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.

    7. Remove the 2 bolts and disconnect the 6 connectors and 12 wire harness clamps.

      A003WHH

  68. SECURE STEERING WHEEL


    1. A003Z0B

      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.

  69. REMOVE COLUMN HOLE COVER SILENCER SHEET


    1. A003ZTF

      Turn back the floor carpet.

    2. Remove the 2 clips and column hole cover silencer sheet.

  70. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A003YG6E01
      Text in Illustration
      *a Matchmark

      Put matchmarks on the No. 2 steering intermediate shaft assembly and steering intermediate shaft.

    2. Remove the bolt.

    3. Separate the No. 2 steering intermediate shaft assembly from the steering intermediate shaft.

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


    1. A003Y1LE05
      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.

  72. REMOVE FRONT NO. 3 ENGINE UNDER COVER (for 2ZR-FXE)


    1. A003X24

      Remove the 4 clips and front No. 3 engine under cover.

  73. REMOVE FRONT NO. 3 ENGINE UNDER COVER (for 5ZR-FXE)


    1. A003X24

      Remove the 4 clips and front No. 3 engine under cover.

  74. REMOVE FRONT CENTER FLOOR BRACE (for 2ZR-FXE)


    1. A003XBU

      Remove the 4 bolts and front center floor brace.

  75. REMOVE FRONT CENTER FLOOR BRACE (for 5ZR-FXE)


    1. A003XBU

      Remove the 4 bolts and front center floor brace.

  76. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2ZR-FXE)

    w/ Exhaust Heat Recirculation System Click here

    w/o Exhaust Heat Recirculation System Click here

  77. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 5ZR-FXE)


    1. A003X4N

      Remove the 2 bolts and 2 compression springs.

    2. Remove the front exhaust pipe assembly from the 2 exhaust pipe supports.

    3. Remove the gasket from the exhaust manifold.

  78. REMOVE FRONT AXLE SHAFT NUT LH


    1. A003WYUE01

      Using SST and a hammer, release the staked part of the front axle shaft nut.

      SST
      09930-00010

      Note

      Loosen the staked part of the nut completely, otherwise the threads of the drive shaft may be damaged.

    2. While applying the brakes, remove the front axle shaft nut.

  79. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  80. SEPARATE FRONT SPEED SENSOR LH


    1. A003YDN

      Remove the bolt and clamp, and separate the front speed sensor and front flexible hose from the front shock absorber with coil spring.

      Note

      Be sure to separate the front speed sensor from the front shock absorber with coil spring completely.

  81. SEPARATE FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  82. SEPARATE TIE ROD END SUB-ASSEMBLY LH


    1. Remove the clip and nut.

    2. A003YRZE03

      Install SST to the tie rod end.

      SST
      09960-20010   ( 09961-02060 )

      Note

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

    3. Secure SST using a string.

      Note

      Be sure to tighten the string firmly to secure SST to the steering knuckle to prevent SST from falling off.

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

      A003V3NE01
      Text in Illustration
      *1 Center Nut - -
      *a String *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


      • 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.

  83. SEPARATE TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  84. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH


    1. A003YJM

      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.

  85. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

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


    1. A003Z94

      Remove the bolt and 2 nuts, and separate the front lower No. 1 suspension arm sub-assembly from the front lower ball joint assembly.

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

    Tech Tips

    Perform the same procedure as for the LH side.

  88. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH


    1. A003XW4E02
      Text in Illustration
      *a Matchmark

      Put matchmarks on the front drive shaft assembly and front axle hub sub-assembly.

    2. Using a plastic hammer, separate the front drive shaft assembly from the front axle assembly. If it is difficult to separate, tap the end of the front drive shaft assembly using a brass bar and a hammer.

      Note

      Be careful not to damage the drive shaft boot.

  89. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH


    1. A003XQ5E01

      Using SST, remove the front drive shaft assembly.

      SST
      09520-00031
      09520-01010

      Note


      • Do not damage the transaxle case oil seal.

      • Do not damage the inboard joint boot.

      • Do not drop the front drive shaft assembly.

  90. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  91. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  92. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH


    1. A003ZQG

      Using a screwdriver, remove the front drive shaft hole snap ring.

  93. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING RH

    Tech Tips

    Perform the same procedure as for the LH side.

  94. INSTALL ENGINE HANGERS


    1. A003X6RE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      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

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

  95. REMOVE STARTER HOLE INSULATOR


    1. A003ZC0

      Remove the 2 bolts and starter hole insulator.

  96. REMOVE FLYWHEEL HOUSING SIDE COVER


    1. A003XIR

      Remove the flywheel housing side cover.

  97. REMOVE FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT


    1. A003XCJ

      Remove the 2 bolts and front engine mounting bracket lower reinforcement.

  98. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH


    1. A003ZUT

      Remove the 4 bolts and rear side rail reinforcement sub-assembly LH.

  99. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  100. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH


    1. A003V95

      Remove the 3 bolts, clip and front suspension member rear brace LH.

  101. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  102. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A003YWP

      Remove the 2 bolts and 2 wiring 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.

      A003VF7
    3. A003VERE01
      Text in Illustration
      *1 Engine Lifter
      *2 Attachment
      A003YGT Attachment placement location

      Support the front suspension crossmember sub-assembly with an engine lifter using 4 attachments or equivalent tools as shown in the illustration.

      Note


      • Make sure to secure the front suspension crossmember sub-assembly to prevent it from dropping.

      • Use the attachments to keep the front suspension crossmember sub-assembly level.

      • The front suspension crossmember sub-assembly is a heavy component. Make sure that it is supported securely.

    4. Remove the 2 bolts and front suspension crossmember sub-assembly.

      A003VNW

    5. Slowly lower the front suspension crossmember sub-assembly.

      Note

      When lowering the front suspension crossmember sub-assembly, be careful not to damage the vehicle body or other components installed on the vehicle.

  103. REMOVE REAR ENGINE MOUNTING INSULATOR (for 2ZR-FXE)


    1. A003YPZ

      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.

  104. REMOVE REAR ENGINE MOUNTING INSULATOR (for 5ZR-FXE)


    1. A003YPZ

      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.

  105. SUPPORT HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. Support the hybrid vehicle transaxle assembly with a transmission jack.

  106. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A003XKI

      Remove the bolt and nut.

    2. A003W05

      Remove the 4 bolts and front crossmember sub-assembly.

  107. REMOVE FRONT ENGINE MOUNTING INSULATOR (for 2ZR-FXE)


    1. A003ZB1

      Remove the 2 bolts and front engine mounting insulator.

  108. REMOVE FRONT ENGINE MOUNTING INSULATOR (for 5ZR-FXE)


    1. A003ZB1

      Remove the 2 bolts and front engine mounting insulator.

  109. REMOVE ENGINE MOUNTING BRACKET LH


    1. A003YD2

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

      Note

      Turn the nut while holding the bolt.

    2. A003VE1

      Remove the 3 bolts and engine mounting bracket LH.

  110. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. A003V4L

      Remove the 7 bolts and hybrid vehicle transaxle assembly.

      Note


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

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

  111. REMOVE FRONT ENGINE MOUNTING BRACKET


    1. A003Y6U

      Remove the 3 bolts and front engine mounting bracket.

  112. REMOVE REAR ENGINE MOUNTING BRACKET


    1. A003VG1

      Remove the 4 bolts and rear engine mounting bracket.

  113. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A003VR6

      Remove the 2 bolts and 2 wire harness clamp brackets.

  114. REMOVE MOTOR CABLE BRACKET


    1. A003VK9

      Remove the bolt and motor cable bracket.

  115. REMOVE GENERATOR CABLE

    Note

    Wear insulated gloves.


    1. A003WLU

      Disconnect the generator cable clamp from the motor cable bracket.

    2. A003ZCL

      Remove the 3 bolts and slide the generator cable connector shell back.

    3. A003ZNO

      Disengage the 2 claws to remove the terminal cap.

    4. A003VFH

      Remove the 3 bolts and generator cable from the hybrid transaxle assembly.

  116. REMOVE MOTOR CABLE

    Note

    Wear insulated gloves.


    1. A003X6A

      Disconnect the 3 clamps.

    2. A003ZKB

      Remove the 2 bolts and slide the motor cable connector shell back.

    3. A003X6V

      Disengage the 2 claws to remove the terminal cap.

    4. A003ZB5

      Remove the 3 bolts and motor cable from the hybrid transaxle assembly.