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ENGINE ASSEMBLY REMOVAL

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PROCEDURE


  1. Click here

    PRECAUTION

    CAUTION:

    • The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

    • The vehicle has a hybrid system that operates at voltages up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this manual to handle the system correctly. Failure to do so may result in serious injury or electrocution (Click here).

    Note:

    After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work (Click here).

  2. Click here

    RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  3. Click here

    DISCHARGE FUEL SYSTEM PRESSURE

    (Click here)

  4. Click here

    REMOVE SERVICE PLUG GRIP

    (Click here)

  5. Click here

    ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  6. Click here

    SECURE STEERING WHEEL

    Click here

  7. Click here

    REMOVE FRONT WHEELS

  8. Click here

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


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

  9. Click here

    REMOVE FRONT WHEEL OPENING EXTENSION PAD RH


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

  10. Click here

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


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

  11. Click here

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


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

  12. Click here

    REMOVE FRONT WHEEL OPENING EXTENSION PAD LH


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

  13. Click here

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


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

  14. Click here

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


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

  15. Click here

    REMOVE FRONT FENDER APRON SEAL LH


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

  16. Click here

    REMOVE FRONT FENDER APRON SEAL RH


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

  17. Click here

    DRAIN ENGINE OIL

    Click here

  18. Click here

    DRAIN COOLANT (for Engine)

    Click here

  19. Click here

    DRAIN COOLANT (for Inverter)

    Click here

  20. Click here

    DRAIN HYBRID TRANSAXLE FLUID

    Click here

  21. Click here

    REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A0005O7

      Lift the rear of the No. 1 engine cover sub-assembly to detach it from the 2 pins.

    2. Lift the front of the No. 1 engine cover sub-assembly to detach it from the pin and remove it.

      Note:

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

  22. Click here

    REMOVE COOL AIR INTAKE DUCT SEAL

    Click here

  23. Click here

    REMOVE CONNECTOR COVER ASSEMBLY

    Click here

  24. Click here

    CHECK TERMINAL VOLTAGE

    Click here

  25. Click here

    TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

    Click here

  26. Click here

    REMOVE INLET AIR CLEANER ASSEMBLY


    1. A0005DB

      Remove the 2 bolts and inlet air cleaner assembly.

  27. Click here

    REMOVE AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  28. Click here

    REMOVE AIR CLEANER FILTER ELEMENT


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

  29. Click here

    REMOVE AIR CLEANER CASE SUB-ASSEMBLY


    1. A0003Y5E03

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

      Table 1. Text in Illustration
      *a Projection
  30. Click here

    REMOVE NO. 5 INVERTER BRACKET

    Click here

  31. Click here

    REMOVE NO. 4 INVERTER BRACKET

    Click here

  32. Click here

    REMOVE UPPER INVERTER COVER

    Click here

  33. Click here

    DISCONNECT GENERATOR CABLE

    Click here

  34. Click here

    REMOVE UPPER INVERTER COVER

    Click here

  35. Click here

    DISCONNECT MOTOR CABLE

    Click here

  36. Click here

    REMOVE NO. 3 MOTOR CABLE BRACKET

    Click here

  37. Click here

    REMOVE CONNECTOR COVER ASSEMBLY

    Click here

  38. Click here

    DISCONNECT NO. 4 ENGINE WIRE

    Click here

  39. Click here

    DISCONNECT FRAME WIRE

    Click here

  40. Click here

    TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY

    Click here

  41. Click here

    DISCONNECT LOW VOLTAGE CONNECTOR

    Click here

  42. Click here

    DISCONNECT NO. 3 ENGINE ROOM WIRE

    Click here

  43. Click here

    REMOVE NO. 4 INVERTER COOLING HOSE

    Click here

  44. Click here

    REMOVE NO. 1 INVERTER COOLING HOSE ASSEMBLY

    Click here

  45. Click here

    REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

  46. Click here

    DISCONNECT NO. 4 ENGINE WIRE


    1. A0007PB

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

  47. Click here

    DISCONNECT ENGINE WIRE


    1. Remove the No. 1 relay block cover.

    2. A0006RQ

      Disconnect the 4 connectors and disengage the wire harness clamp.

    3. A0005BM

      Remove the 2 bolts and disconnect the wire harness and wire harness bracket from the body.

    4. A00086O

      Pull up the lever to disconnect the ECM connector.

    5. Disengage the wire clamp.

  48. Click here

    DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A0005WL

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

    2. Using a screwdriver, disengage the 4 claws and disconnect the transmission control cable assembly with clip from the No. 1 transmission control cable bracket.

    3. Remove the clip from the transmission control cable assembly.

    4. A0005CV

      Disconnect the transmission control cable assembly from the 2 transmission control brackets.

  49. Click here

    DISCONNECT NO. 1 RADIATOR HOSE


    1. A0004KR

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

    2. Slide the clip and disconnect the No. 1 radiator hose.

  50. Click here

    DISCONNECT NO. 2 RADIATOR HOSE


    1. A00061I

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

  51. Click here

    DISCONNECT NO. 5 INVERTER COOLING HOSE


    1. A0005VH

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

  52. Click here

    DISCONNECT INLET HEATER WATER HOSE


    1. A000826

      Slide the clip and disconnect the inlet heater water hose.

  53. Click here

    DISCONNECT OUTLET HEATER WATER HOSE


    1. A0005FH

      Slide the clip and disconnect the outlet heater water hose.

  54. Click here

    DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  55. Click here

    REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A0005V8

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

  56. Click here

    DISCONNECT EARTH WIRE


    1. A0006DU

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

  57. Click here

    REMOVE ENGINE MOVING CONTROL ROD BRACKET


    1. A0005TA

      Remove the 4 bolts and engine moving control rod bracket.

  58. Click here

    REMOVE ENGINE MOVING CONTROL ROD


    1. A0008W2

      Remove the bolt and engine moving control rod and No. 3 engine mounting stay RH from the engine moving control rod bracket.

      Tip:

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

  59. Click here

    DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  60. Click here

    DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

    Click here

  61. Click here

    REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  62. Click here

    SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  63. Click here

    REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  64. Click here

    REMOVE FRONT AXLE SHAFT NUT RH

    Tip:

    Use the same procedure described for the LH side.

  65. Click here

    SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  66. Click here

    SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  67. Click here

    SEPARATE FRONT SPEED SENSOR LH

    Click here

  68. Click here

    SEPARATE FRONT SPEED SENSOR RH

    Tip:

    Use the same procedure described for the LH side.

  69. Click here

    SEPARATE TIE ROD ASSEMBLY LH

    Click here

  70. Click here

    SEPARATE TIE ROD ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  71. Click here

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

    Click here

  72. Click here

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

    Tip:

    Use the same procedure described for the LH side.

  73. Click here

    SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  74. Click here

    SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  75. Click here

    REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  76. Click here

    REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  77. Click here

    REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  78. Click here

    REMOVE FLYWHEEL HOUSING UNDER COVER


    1. A0007X5

      Remove the flywheel housing under cover.

  79. Click here

    REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. A0005NP

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

      Table 2. Text in Illustration
      A00090E Attachment Installation Position
      Note:
      • Install a height adjustment attachment and plate lift attachment under the engine assembly with transaxle.

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

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

      • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed or removed from an engine stand.

      • A000485E01

        To prevent coolant leaks, do not position the height adjustment attachments or plate lift attachments under the No. 2 motor water jacket cover assembly.

        Table 3. Text in Illustration
        *1 No. 2 Motor Water Jacket Cover Assembly
    2. A0004UYE17

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

      Table 4. Text in Illustration
      *a Nut
    3. Remove the 4 bolts, 2 nuts, front suspension member brace rear RH and front suspension member brace rear LH.

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

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

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

    5. Install the engine hangers (Click here).

    6. Using an engine sling device and engine lift, secure the engine assembly.

  80. Click here

    DISCONNECT WIRE HARNESS

    Click here

  81. Click here

    REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly.

  82. Click here

    REMOVE FRONT FRAME ASSEMBLY


    1. A0006PX

      Remove the bolt to disconnect the wire harness clamp bracket from the front frame assembly.

    2. Disengage the 2 clamps to disconnect the No. 4 engine wire from the front engine mounting insulator.

    3. A0007TC

      Remove the nut and separate the engine mounting insulator LH.

    4. A0003WB

      Remove the bolt and separate the front engine mounting insulator.

    5. A0004GX

      Remove the nut and separate the engine mounting insulator RH.

    6. Remove the front frame assembly.

    7. Using height adjustment attachments and plate lift attachments, place the engine assembly on a flat level surface.

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

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

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

  83. Click here

    REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. A0003UV

      Remove the 3 nuts and front engine mounting insulator.

      Tip:

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

  84. Click here

    REMOVE ENGINE MOUNTING INSULATOR LH


    1. A0004GC

      Remove the 2 hole plugs from the front frame assembly.

    2. Remove the 3 nuts and engine mounting insulator LH.

      Tip:

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

  85. Click here

    REMOVE ENGINE MOUNTING INSULATOR RH


    1. A0007ID

      Remove the 2 hole plugs from the front frame assembly.

    2. Remove the 3 nuts and engine mounting insulator RH.

      Tip:

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

  86. Click here

    REMOVE ENGINE MOUNTING BRACKET RH


    1. A0006T4

      Remove the 3 bolts and engine mounting bracket RH.

  87. Click here

    REMOVE DRIVE SHAFT BEARING BRACKET


    1. A0005Y5

      Remove the 3 bolts and drive shaft bearing bracket.

  88. Click here

    REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  89. Click here

    REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

    Click here

  90. Click here

    REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

    Click here

  91. Click here

    REMOVE FLYWHEEL SUB-ASSEMBLY

    Click here

  92. Click here

    INSTALL ENGINE STAND


    1. Install the engine assembly to an engine stand.