ENGINE ASSEMBLY REMOVAL

  1. PRECAUTION

    CAUTION:

    • The engine assembly with transmission 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 650V. 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. RECOVER REFRIGERANT FROM AIR CONDITIONING SYSTEM

    1. Turn the power switch on (READY).

    2. Turn the A/C switch on.

    3. Operate the cooler compressor under the conditions shown below:

      Item Condition
      Engine Speed Idling
      Operating Time 3 minutes or more
      A/C Switch Status ON
      Blower Switch Status HI
      Set Temperature MAX COOL

      This cause most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

      Tech Tips

      It is not necessary to operate the cooler compressor if the A/C does not operate because of compressor lock etc.

    4. Turn the power switch off.

    5. Recover the refrigerant from the air conditioning system using a refrigerant recovery unit.

      Tech Tips

      Use the refrigerant recover unit in accordance with the manufacturer's instruction manual.

  3. REMOVE LUGGAGE TRIM SERVICE HOLE COVER

    1. Disengage the claw to remove the luggage trim service hole cover.

      A011YZM

  4. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL

    Note

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

  5. REMOVE SPARE WHEEL COVER ASSEMBLY

    1. Remove the spare wheel cover assembly.

  6. REMOVE BAGGAGE HOLDER NET (w/ Partition Net)

    1. Remove the baggage holder net.

  7. REMOVE LUGGAGE COMPARTMENT FRONT TRIM COVER

    1. Disengage the 8 fasteners.

      A011XNJ

    2. Disengage the 3 claws and remove the luggage compartment front trim cover.

  8. REMOVE NO. 8 HYBRID VEHICLE BATTERY SHIELD PANEL

    1. Remove the 2 nuts and No. 8 hybrid vehicle battery shield panel.

      A011XZP

  9. 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 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.

      A011WXL

      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.

  10. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  11. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  12. SECURE STEERING WHEEL

    1. Secure the steering wheel with the seat belt in order to prevent rotation.

      A011Y8L

      Tech Tips

      This operation is useful to prevent damage to the spiral cable.

  13. REMOVE FRONT WHEELS

  14. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH

  15. REMOVE ENGINE UNDER COVER LH

  16. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH

  17. REMOVE ENGINE UNDER COVER RH

  18. REMOVE FRONT FENDER APRON SEAL LH

  19. REMOVE FRONT FENDER APRON SEAL RH

  20. DRAIN ENGINE OIL

    1. Remove the oil filler cap.

    2. Remove the oil pan drain plug and gasket, and drain the engine oil into a container.

    3. Clean the oil pan drain plug and install a new gasket and the oil pan drain plug.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  21. DRAIN COOLANT (for Engine)

    Note

    Do not remove the radiator cap sub-assembly or 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.

    1. Loosen the radiator drain cock plug.

    2. Remove the radiator cap sub-assembly.

      A011Z6FE01
      Text in Illustration
      *1 Radiator Cap Sub-assembly *2 Radiator Drain Cock Plug

      Tech Tips

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

  22. 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.

      A011XF4

      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 }

  23. DRAIN HYBRID TRANSAXLE FLUID

    1. Using a 10 mm hexagon socket wrench, remove the filler plug and gasket.

      A011YBTE01
      Text in Illustration
      *1 Filler Plug
      *2 Drain Plug

    2. Using a 10 mm hexagon socket wrench, remove the drain plug and gasket to drain the hybrid transaxle fluid.

    3. Using a 10 mm hexagon socket wrench, install the drain plug and a new gasket.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  24. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

    1. Lift the rear of the engine cover to detach the cover from the 2 pins, and then lift the front of the engine cover to detach the cover from the pin and remove the No. 1 engine cover sub-assembly.

      A011WEI

      Note

      Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover sub-assembly to break.

  25. REMOVE COOL AIR INTAKE DUCT SEAL

    1. Remove the 7 clips and cool air intake duct seal.

      A011YZX

  26. REMOVE CONNECTOR COVER ASSEMBLY

    CAUTION:

    • Do not touch the high voltage connectors and terminals for 10 minutes after the service plug grip is removed.

    • Wear insulated gloves.

    Note

    Do not start the hybrid system with the service plug grip removed because it may cause a malfunction.

    1. Remove the 2 bolts and connector cover assembly.

      A011YJW

      Note

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

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

  27. CHECK TERMINAL VOLTAGE

    CAUTION:

    Wear insulated 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.

      A011VIF
      Standard voltage
      0 V

      Tech Tips

      Use a measuring range of DC 750 V or more on the voltmeter.

  28. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated gloves.

    1. Temporarily install the connector cover assembly with the bolt to prevent any foreign objects or water from entering the inverter with converter assembly.

      A011WFV

  29. REMOVE INLET AIR CLEANER ASSEMBLY

    1. Remove the 2 bolts and inlet air cleaner assembly.

      A011XL7

  30. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    1. Disconnect the mass air flow meter connector and wire harness clamp from the air cleaner cap sub-assembly.

      A011XH2

    2. Disconnect the ventilation hose from the cylinder head cover.

    3. Disconnect the connector and wire harness clamp.

    4. Release the 2 clamps and remove the air cleaner cap sub-assembly.

      A011Z7E

    5. Disconnect the 2 fuel vapor feed hoses.

      A011VTWE01
      Text in Illustration
      *1 Retainer
      *2 Fuel Tube Connector
      *3 Pipe
      *4 O-ring
      *a Pinch
      *b Pull

      Note

      • Remove any dirt or foreign matter on the fuel tube connector before performing this work.

      • Do not allow any scratches or foreign matter to get on the parts when disconnecting them as the fuel tube connector has an O-ring that seals the pipe.

      • Perform this work by hand. Do not use any tools.

      • Protect the disconnected parts by covering them with plastic bags after disconnecting each fuel vapor feed hose.

    6. Loosen the hose clamp and disconnect the air cleaner hose from the throttle with motor body assembly.

      A011VTT

  31. REMOVE AIR CLEANER FILTER ELEMENT

    1. Remove the air cleaner filter element.

  32. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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

      A011Z2GE03
      Text in Illustration
      *a Projection

  33. REMOVE NO. 5 INVERTER BRACKET

    1. Remove the 2 bolts and No. 5 inverter bracket.

      A011VFL

  34. REMOVE NO. 4 INVERTER BRACKET

    1. Remove the 3 bolts and No. 4 inverter bracket.

      A011Z1D

  35. REMOVE UPPER INVERTER COVER

    CAUTION:

    Wear insulated gloves.

    1. Remove the 2 bolts and upper inverter cover (generator cable side).

      A011YVG

      Note

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

      • Do not touch the upper inverter cover waterproofing rubber.

  36. DISCONNECT GENERATOR CABLE

    CAUTION:

    Wear insulated gloves.

    1. Using an insulated tool, remove the 3 bolts.

      A011X0V

    2. Disconnect the 2 wire harness clamps and separate the generator cable.

      A011XU2

      Note

      • Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them.

      • Do not touch the connector waterproofing rubber or terminals.

      • Insulate the removed terminals with insulating tape.

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

  37. REMOVE UPPER INVERTER COVER

    CAUTION:

    Wear insulated gloves.

    1. Remove the 2 bolts and upper inverter cover (motor cable side).

      A011W78

      Note

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

      • Do not touch the upper inverter cover waterproofing rubber.

  38. DISCONNECT MOTOR CABLE

    CAUTION:

    Wear insulated gloves.

    1. Using an insulated tool, remove the 3 bolts.

      A011YBO

    2. Disconnect the 3 wire harness clamps and separate the motor cable.

      A011XSB

      Note

      • Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them.

      • Do not touch the connector waterproofing rubber or terminals.

      • Insulate the removed terminals with insulating tape.

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

  39. REMOVE NO. 3 MOTOR CABLE BRACKET

    1. Disconnect the hose clamp from the No. 3 motor cable bracket.

      A011Y62

      Tech Tips

      Do not remove the hose clamp from the hose.

    2. Remove the 2 bolts and No. 3 motor cable bracket.

  40. REMOVE CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated gloves.

    1. Remove the bolt and connector cover assembly.

      A011XGL

      Note

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

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

  41. DISCONNECT NO. 4 ENGINE WIRE

    CAUTION:

    Wear insulated gloves.

    1. Disconnect the No. 4 engine wire.

      A011YEI

      Note

      • Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them.

      • Do not touch the connector waterproofing rubber or terminals.

      • Insulate the removed terminals with insulating tape.

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

    2. Disconnect the wire harness clamp.

      A011WGD

  42. DISCONNECT NO. 4 FLOOR WIRE

    CAUTION:

    Wear insulated gloves.

    1. Remove the bolt.

      A011YCT

    2. Disconnect the wire harness clamp and connector.

      A011WBF

      Note

      • Do not damage the terminals, connector housings or inverter with converter assembly when disconnecting them.

      • Do not touch the connector waterproofing rubber or terminals.

      • Insulate the removed terminals with insulating tape.

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

  43. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

    CAUTION:

    Wear insulated gloves.

    1. Temporarily install the connector cover assembly with the bolt to prevent any foreign objects or water from entering the inverter with converter assembly.

      A011WFV

  44. DISCONNECT LOW VOLTAGE CONNECTOR

    Note

    • Insulate the removed terminals with insulating tape.

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

    1. Raise the lock lever and disconnect the 3 low voltage connectors.

      A011YSH

    2. Disconnect the low voltage connector from the inverter with converter assembly.

  45. DISCONNECT NO. 3 ENGINE ROOM WIRE

    1. Remove the relay block cover.

    2. Remove the nut.

      A011VXM

    3. Disconnect the wire harness clamp and No. 3 engine room wire.

  46. REMOVE NO. 4 INVERTER COOLING HOSE

    1. Release the retainer and disconnect the No. 4 inverter cooling hose from the inverter with converter assembly.

      A011XBOE01
      Text in Illustration
      *1 Retainer

    2. Put pieces of cloth into the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags as shown in the illustration to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

      A011YJQ

  47. REMOVE NO. 1 INVERTER COOLING HOSE ASSEMBLY

    1. Release the retainer and disconnect the No. 1 inverter cooling hose from the inverter with converter assembly.

      A011XI1E01
      Text in Illustration
      *1 Retainer

    2. Put pieces of cloth into the pipes and in the disconnected hoses, or cover the pipes and hoses with plastic bags as shown in the illustration to prevent foreign matter from entering the cooling system and to prevent coolant from spilling near the inverter with converter assembly.

      A011WYL

  48. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    CAUTION:

    Wear insulated gloves.

    1. Temporarily secure the No. 3 engine room wire with the inverter with converter assembly hook as shown in the illustration.

      A011WHQE01
      Text in Illustration
      *1 No. 3 Engine Room Wire
      *2 Hook

    2. Remove the 2 bolts, nut and inverter with converter assembly.

      A011XFV

      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.

    3. Even after the coolant is drained, coolant remains in the inverter with converter assembly due to its internal structure. Therefore, seal or cover the pipes when removing the inverter with converter to prevent coolant from spilling out or foreign matter from entering the inverter with converter.

      A011VYE

  49. DISCONNECT NO. 4 ENGINE WIRE

    1. Remove the 3 wire harness clamps and disconnect the No. 4 engine wire from the fan shroud.

      A011XSO

  50. DISCONNECT ENGINE WIRE

    1. Disconnect the 4 connectors and disconnect the wire harness clamp.

      A011W50

    2. Remove the bolt and disconnect the earth wire from the body.

      A011VPG

    3. Pull up the lever to disconnect the ECM connector.

      A011VD5

    4. Disconnect the wire clamp.

  51. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    1. Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.

      A011WV2

    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.

      A011W8R

  52. DISCONNECT NO. 1 RADIATOR HOSE

    1. Remove the hose clamp to disconnect the air fuel ratio sensor wire from the No. 1 radiator hose.

      A011XRC

    2. Disconnect the No. 1 radiator hose.

  53. DISCONNECT NO. 5 INVERTER COOLING HOSE

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

      A011YY0

  54. DISCONNECT INLET HEATER WATER HOSE

    1. Disconnect the inlet heater water hose.

      A011YWA

  55. DISCONNECT OUTLET HEATER WATER HOSE

    1. Disconnect the outlet heater water hose.

      A011VSJ

  56. DISCONNECT FUEL MAIN TUBE

    1. Release the claw and remove the No. 1 EFI fuel pipe clamp.

      A011WTB

    2. Pinch the fuel tube connector and then pull out the fuel main tube.

      A011YTP

      Note

      • Check for dirt and foreign objects on the pipe and around the connector. Clean if necessary and then disconnect the connector.

      • Disconnect the connector by hand.

      • Do not bend, fold or rotate the nylon tube.

      • If the pipe and connector are stuck together, push and pull the connector until it becomes free.

      • Put the pipe and connector ends in vinyl bags to prevent damage and contamination.

  57. REMOVE NO. 2 ENGINE MOUNTING STAY RH

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

      A011WOM

  58. SEPARATE EARTH WIRE

    1. Remove the bolt and separate the earth wire from the engine moving control rod bracket.

      A011XQW

  59. REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY

    1. Remove the 4 bolts and engine moving control rod sub-assembly.

      A011XDZ

  60. REMOVE ENGINE MOVING CONTROL ROD

    1. Remove the bolt and engine moving control rod from the engine moving control rod bracket.

      A011WLF

      Tech Tips

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

  61. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

    1. Remove the bolt and disconnect the suction hose sub-assembly from the compressor with motor assembly.

      A011VJN

    2. Remove the O-ring from the suction hose sub-assembly .

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  62. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    1. Remove the bolt and disconnect the No. 1 cooler refrigerant discharge hose from the compressor with motor assembly.

      A011YSW

    2. Remove the O-ring from the No. 1 cooler refrigerant discharge hose.

      Note

      Seal the openings of the disconnected parts using vinyl tape to prevent entry of moisture and foreign matter.

  63. DISCONNECT NO. 2 RADIATOR HOSE

    1. Disconnect the No. 2 radiator hose.

      A011VEB

  64. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    1. Disconnect the heated oxygen sensor connector.

      A011YAC

    2. Remove the 2 bolts, 2 compression springs and 2 nuts.

      A011YJI

    3. Remove the front exhaust pipe assembly from the exhaust pipe support.

    4. Remove the 2 gaskets from the exhaust manifold converter sub-assembly and front exhaust pipe assembly.

  65. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

    1. Put matchmarks on the steering intermediate shaft assembly and steering link assembly.

      A011VCLE02
      Text in Illustration
      *a Matchmark

    2. Remove the bolt.

    3. Separate the steering intermediate shaft assembly from the steering link assembly.

  66. REMOVE FRONT AXLE SHAFT NUT LH

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

      A011Y6WE01
      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.

  67. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure described for the LH side.

  68. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

    1. Remove the nut and separate the front stabilizer link assembly from the front shock absorber assembly.

      A011Z71

      If the ball joint turns together with the nut, use a wrench to hold the stud bolt.

  69. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  70. SEPARATE FRONT SPEED SENSOR LH

    1. Remove the bolt, disengage the clamp and separate the front speed sensor and front flexible hose.

      A011WHX

      Note

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

    2. Remove the bolt and front speed sensor from the steering knuckle.

      A011VT6

      Note

      • Prevent foreign matter from contacting the sensor tip.

      • Be careful not to damage the front speed sensor.

      • Clean the speed sensor installation hole and the contact surfaces every time the speed sensor is removed.

  71. SEPARATE FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  72. SEPARATE TIE ROD ASSEMBLY LH

    1. Remove the cotter pin and nut.

      A011YDD

    2. Install SST to the tie rod assembly LH.

      A011WYSE01
      SST
      09960-20010   ( 09961-02060 )

      Note

      Make sure that the lower ends of the tie rod assembly LH 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 assembly LH from the steering knuckle.

      A011VH8E02
      Text in Illustration
      *1 Center Nut - -
      *a String *b Grease Application Area
      A011XJ4 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.

  73. SEPARATE TIE ROD ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

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

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

      A011XUZ

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

    Tech Tips

    Use the same procedure described for the LH side.

  76. SEPARATE FRONT AXLE ASSEMBLY LH

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

      A011VSHE01
      Text in Illustration
      *a Matchmark

    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.

  77. SEPARATE FRONT AXLE ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  78. REMOVE FLYWHEEL HOUSING UNDER COVER

    1. Remove the flywheel housing under cover.

      A011VZK

  79. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

    1. Set an engine lifter.

      A011VOR
      Text in Illustration
      A011WQU Attachment Installation Position

      Note

      • Install a height adjustment attachment and plate lift attachment onto 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 onto the oil pan of the engine assembly with transaxle.

      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.

      • Do not perform any procedure 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.

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

      A011YY7E03
      Text in Illustration
      *1 Nut

    3. Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH.

    4. Operate the engine lifter and remove the engine assembly from the vehicle.

      Note

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

      • While lowering the engine from the vehicle, do not allow it to contact the vehicle.

    5. Install the engine hangers Click here.

  80. REMOVE ENGINE WIRE

    1. Remove the engine wire from the engine with transaxle.

  81. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    1. Using SST, remove the front drive shaft assembly LH.

      A011XFTE01
      SST
      09520-00031
      09520-01010

      Note

      • Do not damage the hybrid vehicle transaxle assembly type T oil seal.

      • Do not damage the front axle inboard joint boot.

      • Do not drop the front drive shaft assembly LH.

  82. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

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

      A011XWR

  83. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    1. Separate the bearing bracket hole snap ring from the drive shaft bearing bracket.

      A011XNL

    2. Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket.

      Note

      • Do not damage the hybrid vehicle transaxle assembly type T oil seal.

      • Do not damage the front axle inboard joint boot.

      • Do not drop the front drive shaft assembly RH.

    3. Remove the bearing bracket hole snap ring from the front drive shaft assembly RH.

  84. REMOVE FRONT FRAME ASSEMBLY

    1. Remove the bolt and disconnect the No. 4 engine wire from the front frame assembly.

      A011Y1B

    2. Remove the nut and separate the engine mounting insulator LH.

      A011WMZ

    3. Remove the bolt and separate the front engine mounting insulator.

      A011X5H

    4. Remove the nut and separate the engine mounting insulator RH.

      A011X3Q

    5. Remove the front frame assembly.

    6. Using a height adjustable attachment and plate lift attachment, place the engine assembly on a flat level surface.

      Note

      • Using a height adjustable attachment and plate lift attachment, place the engine assembly with transaxle horizontally.

      • To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle.

      • Using an engine sling device and engine lift, secure the engine assembly before service.

  85. REMOVE FRONT ENGINE MOUNTING INSULATOR

    1. Remove the 3 nuts and front engine mounting insulator.

      A011Y9R

      Tech Tips

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

  86. REMOVE ENGINE MOUNTING INSULATOR LH

    1. Remove the 2 hole plugs from the front frame assembly.

      A011VY7

    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.

  87. REMOVE ENGINE MOUNTING INSULATOR RH

    1. Remove the 2 hole plugs from the front frame assembly.

      A011VQO

    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.

  88. REMOVE ENGINE MOUNTING BRACKET RH

    1. Remove the 3 bolts and engine mounting bracket RH.

      A011WL1

  89. REMOVE DRIVE SHAFT BEARING BRACKET

    1. Remove the 3 bolts and drive shaft bearing bracket.

      A011VR7

  90. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

    1. Using the transmission jack attachment, set the hybrid vehicle transaxle assembly on a transmission jack.

      Note

      • Secure the hybrid vehicle transaxle assembly to the transmission jack using a suitable adapter, such as a rope or attachment.

      • To prevent the motor water jacket cover assembly from deforming, do not place any attachments onto the motor water jacket cover assembly of the hybrid vehicle transaxle assembly.

      • Hold the engine assembly with a suitable adapter, such as a rope, during the operation.

    2. Remove the 9 bolts and hybrid vehicle transaxle assembly.

      A011Z4R

      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.

  91. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

    1. Using SST, hold the crankshaft pulley.

      A011WGUE04
      SST
      09213-54015
      09330-00021
      91551-80650

    2. Remove the 6 bolts and transmission input damper assembly.

      A011Z6R

  92. REMOVE FLYWHEEL SUB-ASSEMBLY

    1. Using SST, hold the crankshaft pulley.

      A011WGUE04
      SST
      09213-54015
      09330-00021
      91551-80650

    2. Remove the 8 bolts and flywheel sub-assembly.

      A011WMJ

  93. INSTALL ENGINE STAND

    1. Install the engine onto an engine stand with the bolts.