ENGINE ASSEMBLY REMOVAL

PROCEDURE


  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 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. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. REMOVE SERVICE PLUG GRIP

    Click here

  4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  5. REMOVE FRONT WHEEL

  6. REMOVE REAR ENGINE UNDER COVER LH

  7. REMOVE REAR ENGINE UNDER COVER RH

  8. REMOVE FRONT LOWER BUMPER ABSORBER

  9. REMOVE NO. 1 ENGINE UNDER COVER

  10. REMOVE NO. 2 ENGINE UNDER COVER

  11. DRAIN ENGINE OIL

    Click here

  12. DRAIN COOLANT (for Engine)

    Click here

  13. DRAIN COOLANT (for Inverter)

    Click here

  14. DRAIN HYBRID TRANSAXLE FLUID

    Click here

  15. REMOVE NO. 2 CYLINDER HEAD COVER


    1. B005Y8A

      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 No. 2 cylinder cover to break.

      • Pull the No. 2 cylinder cover straight up to remove it. Attempting to pull the No. 2 cylinder cover forward may cause it to break.

  16. REMOVE RADIATOR SUPPORT OPENING COVER

    Click here

  17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. B005XEF

      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.

  18. REMOVE INLET AIR CLEANER ASSEMBLY


    1. B005ZP6

      Remove the 2 bolts and inlet air cleaner assembly.

  19. REMOVE AIR CLEANER CASE


    1. B005ZTK

      Separate the 3 clamps and No. 4 water by-pass hose from the air cleaner case.

    2. Remove the 3 bolts and air cleaner case.

  20. REMOVE AIR CLEANER HOSE ASSEMBLY

    Click here

  21. REMOVE NO. 1 INVERTER BRACKET

    Click here

  22. DISCONNECT ENGINE ROOM MAIN WIRE

    Click here

  23. REMOVE INVERTER COVER

    Click here

  24. CHECK TERMINAL VOLTAGE

    Click here

  25. DISCONNECT FRAME WIRE

    Click here

  26. DISCONNECT GENERATOR CABLE

    Click here

  27. DISCONNECT MOTOR CABLE

    Click here

  28. DISCONNECT NO. 2 ENGINE WIRE

    Click here

  29. INSTALL INVERTER COVER

    Click here

  30. DISCONNECT NO. 2 ENGINE ROOM WIRE

    Click here

  31. DISCONNECT WATER HOSE

    Click here

  32. REMOVE INVERTER WITH CONVERTER ASSEMBLY

    Click here

  33. REMOVE INVERTER RESERVE TANK ASSEMBLY


    1. B005ZOX

      Remove the 2 bolts and inverter reserve tank assembly.

  34. REMOVE INVERTER TRAY BRACKET


    1. B005Y5K

      Separate the 2 clamps.

    2. Remove the 5 bolts and inverter tray bracket.

  35. DISCONNECT NO. 1 RADIATOR HOSE


    1. B005XUE

      Slide the clamp and disconnect the No. 1 radiator hose from the radiator pipe.

  36. DISCONNECT NO. 2 RADIATOR HOSE


    1. B005YSN

      Slide the clamp and disconnect the No. 2 radiator hose from the water inlet.

  37. DISCONNECT NO. 4 WATER BY-PASS HOSE


    1. B005YY6

      Slide the clamp and disconnect the No. 4 water by-pass hose from the radiator pipe.

  38. DISCONNECT NO. 3 INVERTER COOLING HOSE


    1. B005XJ8

      Slide the clamp and disconnect the No. 3 inverter cooling hose from the hybrid vehicle transaxle assembly.

  39. DISCONNECT NO. 5 INVERTER COOLING HOSE


    1. B005ZBG

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

  40. DISCONNECT OUTLET HEATER WATER HOSE


    1. B005Y7K

      Slide the clamp and disconnect the outlet heater water hose.

  41. DISCONNECT INLET HEATER WATER HOSE


    1. B005Z25

      Slide the clamp and disconnect the inlet heater water hose.

  42. DISCONNECT HEATER HOSE


    1. B005XYI

      Slide the clamp and disconnect the heater hose.

  43. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. B005XZU

      Slide the clamp and disconnect the No. 1 fuel vapor feed hose.

  44. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. B005Y36

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

    2. B005XVC

      Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.

      Note


      • Remove any dirt and foreign matter from the fuel tube connector before performing this work.

      • Do not allow any scratches or foreign matter to get on the parts when disconnecting, as the fuel tube connector has the O-rings that seal the pipe.

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

      • Do not forcibly bend, kink or twist the nylon tube.

      • Protect the disconnected parts by covering them with plastic bags after disconnecting the fuel tube.

      • If the fuel tube connector and pipe are stuck, push and pull to release them.

  45. SEPARATE COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  46. DISCONNECT ENGINE WIRE


    1. B005YKA

      Disconnect the 2 clamps.

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

    3. B005ZMS

      Disconnect the 2 connectors, 2 clamps and engine wire from the engine room junction block.

    4. B005ZAY

      Disconnect the 3 clamps.

    5. B005ZUN

      Remove the bolt and disconnect the earth wire.

    6. B005XHP

      Disconnect the 2 clamps and engine wire.

  47. SECURE STEERING WHEEL

    Click here

  48. REMOVE COLUMN HOLE COVER SILENCER SHEET (for LHD)

    Click here

  49. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for LHD)

    Click here

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

    Click here

  51. REMOVE FRONT NO. 3 ENGINE UNDER COVER

    Click here

  52. REMOVE FRONT CENTER FLOOR BRACE

    Click here

  53. REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/ Exhaust Heat Recirculation System)

    Click here

  54. REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/o Exhaust Heat Recirculation System)

    Click here

  55. REMOVE FRONT AXLE SHAFT NUT LH

    Click here

  56. REMOVE FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  57. SEPARATE FRONT SPEED SENSOR LH

    Click here

  58. SEPARATE FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  59. SEPARATE TIE ROD END SUB-ASSEMBLY LH

    Click here

  60. SEPARATE TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  61. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  62. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

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

    Click here

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

    Tech Tips

    Perform the same procedure as for the LH side.

  65. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  66. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  67. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  68. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  69. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  70. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING RH

    Tech Tips

    Perform the same procedure as for the LH side.

  71. REMOVE FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT

    Click here

  72. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  73. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Click here

  74. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  75. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  76. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  77. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. B005Z0Z

      Set an engine lifter.

      Note

      Place the engine assembly on wooden blocks or equivalent so that the engine assembly is level.

    2. B005Z6C

      Remove the 4 bolts and separate the front crossmember sub-assembly.

    3. B005XM6

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

    4. B005XMU

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

    5. Carefully remove the engine assembly with transaxle from the vehicle.

    6. B005Y3CE01
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the No. 1 engine hanger and No. 2 engine hanger 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

    7. Attach an engine sling device and hang the engine assembly with a chain block.

  78. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY


    1. B005YB4

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

  79. REMOVE FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B005Z4S

      Remove the 2 bolts and front engine mounting insulator.

  80. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B005ZHS

      Remove the through bolt and rear engine mounting insulator.

  81. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B005Y9W

      Remove the 4 bolts and engine mounting insulator LH.

  82. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

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


    1. B005ZOM

      Remove the 2 bolts and 2 cooler brackets.

    2. Disconnect the earth wire clamp from the engine mounting insulator sub-assembly RH.

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

  83. REMOVE RADIATOR PIPE


    1. B005ZKZ

      Slide the clamp and remove the No. 3 radiator hose from the cylinder head.

    2. Remove the 2 bolts and radiator pipe.

  84. REMOVE STARTER HOLE INSULATOR

    Click here

  85. REMOVE FLYWHEEL HOUSING SIDE COVER

    Click here

  86. REMOVE ENGINE WIRE


    1. Disconnect all the wire harnesses and connectors. Make sure that no wire harnesses are connected to the engine assembly.

  87. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. Remove the hybrid vehicle transaxle assembly Click here.

      Note

      Be careful not to apply excessive force to the transmission input damper assembly when removing or installing the hybrid vehicle transaxle assembly. If excessive force is applied, the transmission input damper assembly may be damaged, or its splines may become misaligned.

  88. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY


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

      Note

      This step should be done while hanging the engine assembly using the engine hangers and a chain block.

    2. Remove the transmission input damper assembly Click here.

  89. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. Remove the flywheel sub-assembly Click here.