ENGINE ASSEMBLY > REMOVAL

for Preparation Click here

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.

CAUTION:

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).

NOTICE:

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 auxiliary battery terminal notice before proceeding with work (Click here).

1. Remove the rear No. 2 floor board.
   

1. Remove the rear deck floor box.
   

1. Remove the rear No. 3 floor board.
   

1. Remove the clip.
   

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

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

NOTICE:

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

CAUTION:

1. Wear insulating gloves.
   
2. Remove the service plug grip to interrupt the high voltage circuit at the time of inspection or repair.
   
3. Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
   
4. 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.
   
   

   
   
   
   

   CAUTION:

   1. Keep the removed service plug grip in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
      
   2. After removing the service plug grip, do not touch the high voltage connectors or terminals for 10 minutes.
      

   HINT:

   Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

1. Remove the oil filler cap.
   

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

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

   Torque:

   37 N*m{ 377 kgf*cm , 27 ft.*lbf }

NOTICE:

Do not remove the reserve 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.

1. Loosen the radiator drain cock plug.
   

   HINT:

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

2. Remove the reserve tank cap and drain the coolant.
   
   

   
   
   
   
   

   Text in Illustration 

   *1

   Reserve Tank Cap

   *2

   Radiator Drain Cock Plug

NOTICE:

1. Do not reuse the drained coolant because it may contain foreign objects.
   
2. 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 }

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

   Text in Illustration 

   *1	Filler Plug
   *2	Drain Plug

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:

   39 N*m{ 398 kgf*cm , 29 ft.*lbf }

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

   NOTICE:

   1. Disengage the clips in the order shown in the illustration.
      
   2. Attempting to disengage both front and rear clips at the same time may cause the cover to break.
      
   3. Pull the cover straight up to remove. Attempting to pull the cover forward may cause it to break.
      

1. 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.
   

1. 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.
   

1. 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.
   

1. Loosen the hose clamp and separate the ventilation hose.
   

2. Unlock the hose clamp and remove the air cleaner hose assembly.
   

1. Remove the 9 clips and radiator support opening cover.
   

1. Remove the 2 clips
   

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

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

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.
   

CAUTION:

Wear insulating gloves.

1. Remove the 9 bolts and inverter cover.
   

   NOTICE:

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

CAUTION:

Wear insulating gloves.

NOTICE:

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
   

   HINT:

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

CAUTION:

Wear insulating gloves.

NOTICE:

1. Insulate the disconnected terminals with insulating tape.
   
2. Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.
   

1. Disconnect the 2 harness clamps.
   

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

CAUTION:

Wear insulating gloves.

NOTICE:

1. Insulate the disconnected terminals with insulating tape.
   
2. Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.
   

1. Turn back the wire harness cover and release the cable.
   

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

CAUTION:

Wear insulating gloves.

NOTICE:

1. Insulate the disconnected terminals with insulating tape.
   
2. Cover the hole where the cable was connected with tape or equivalent (non-residue type) to prevent entry of foreign matter.
   

1. Disconnect the harness clamp.
   

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

CAUTION:

Wear insulating gloves.

NOTICE:

1. Insulate the disconnected terminals with insulating tape.
   
2. 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.
   

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

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.
   

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

   Text in Illustration 

   *1

   Retainer

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

   Text in Illustration 

   *1

   Retainer

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.
   

CAUTION:

Wear insulating gloves.

1. Remove the 3 bolts and inverter with converter assembly.
   

   NOTICE:

   1. 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.
      
   2. To prevent damage, do not hold the inverter with converter assembly by the connectors.
      
   3. 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.
   

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

1. Separate the 2 clamps.
   

2. Remove the 5 bolts and inverter tray bracket.
   

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

1. Disconnect the No. 2 radiator hose from the water inlet.
   

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

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

   Text in Illustration 

   *1	No. 3 Inverter Cooling Hose
   *2	No. 5 Inverter Cooling Hose

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

1. Disconnect the outlet heater water hose.
   

1. Disconnect the inlet heater water hose.
   

1. Disconnect the heater hose.
   

1. Disconnect the No. 1 fuel vapor feed hose.
   

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

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

   NOTICE:

   1. Remove any dirt and foreign matter from the fuel tube connector before performing this work.
      
   2. 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.
      
   3. Perform this work by hand. Do not use any tools.
      
   4. Do not forcibly bend, kink or twist the nylon tube.
      
   5. Protect the disconnected parts by covering them with plastic bags after disconnecting the fuel tube.
      
   6. If the fuel tube connector and pipe are stuck, push and pull to release them.
      

1. Release the green-colored lock and disconnect the connector <A> as shown in the illustration.
   

   CAUTION:

   Wear insulated gloves when performing the procedures.

   NOTICE:

   Insulate the connector by sealing it with tape.

   Text in Illustration 

   *a	Green-colored Lock

2. Disconnect the connector <B>.
   

3. Remove the bolt, 2 nuts and electric inverter compressor.
   

4. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
   

1. Disconnect the 2 clamps.
   

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

3. Disconnect the 2 connectors and 2 clamps from the engine room junction block and separate the wire harness.
   

4. Disconnect the 2 clamps.
   

5. Remove the bolt and disconnect the earth wire.
   

6. Disconnect the 2 clamps and wire harness.
   

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

   HINT:

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

1. Turn back the floor carpet.
   

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

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

   Text in Illustration 

   *a

   Matchmark

2. Remove the bolt.
   

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

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

   Text in Illustration 

   *1	Clip A
   *2	Clip B
   *a	Lip

   NOTICE:

   Do not damage clips A and B.

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

1. Remove the 4 bolts and front center floor brace.
   

CAUTION:

Perform this procedure when the coolant is not hot.

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 2 exhaust pipe supports.
   

5. Remove the 2 gaskets from the front exhaust pipe assembly and exhaust manifold.
   

1. Disconnect the 3 clamps and oxygen sensor connector.
   

2. Remove the 4 bolts and 4 compression springs.
   

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

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

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

   SST

   09930-00010  
   

   NOTICE:

   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.
   

HINT:

Perform the same procedure as for the LH side.

1. Remove the 2 bolts and disengage the clamp, and separate the front speed sensor.
   

   NOTICE:

   1. Be sure to separate the front speed sensor from the front shock absorber completely.
      
   2. Prevent foreign matter from contacting the sensor tip.
      
   3. Be careful not to damage the front speed sensor.
      
   4. Clean the speed sensor installation hole and the contact surfaces every time the speed sensor is removed.
      

HINT:

Perform the same procedure as for the LH side.

1. Remove the clip and nut.
   

2. Install SST to the tie rod end.
   

   SST

   09960-20010   (09961-02060)
   

   NOTICE:

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

3. Secure SST using a string.
   

   NOTICE:

   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.
   
   

   
   
   
   
   

   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.

   NOTICE:

   1. Install SST with the center nut so that A and B shown in the illustration are parallel. Otherwise, the dust cover may be damaged.
      
   2. Be sure to place the wrench on the part indicated in the illustration.
      
   3. Do not damage the front disc brake dust cover.
      
   4. Do not damage the ball joint dust cover.
      
   5. Do not damage the steering knuckle.
      

HINT:

Perform the same procedure as for the LH side.

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

   HINT:

   If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud bolt.

HINT:

Perform the same procedure as for the LH side.

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.
   

HINT:

Perform the same procedure as for the LH side.

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

   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.
   

   NOTICE:

   Be careful not to damage the drive shaft boot.

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

   SST

   09520-00031  
   09520-01010  
   

   NOTICE:

   1. Do not damage the transaxle case oil seal.
      
   2. Do not damage the inboard joint boot.
      
   3. Do not drop the front drive shaft assembly.
      

HINT:

Perform the same procedure as for the LH side.

HINT:

Perform the same procedure as for the LH side.

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

HINT:

Perform the same procedure as for the LH side.

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

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

HINT:

Perform the same procedure as for the LH side.

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

HINT:

Perform the same procedure as for the LH side.

1. 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.
   
   

   
   
   
   

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

   Text in Illustration 

   *1	Engine Lifter
   *2	Attachment
   	Attachment placement location

   NOTICE:

   1. Make sure to secure the front suspension crossmember sub-assembly to prevent it from dropping.
      
   2. Use the attachments to keep the front suspension crossmember sub-assembly level.
      
   3. 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.
   
   

   
   
   
   

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

   NOTICE:

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

1. Set the engine lifter.
   

   NOTICE:

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

2. Remove the 4 bolts to separate the front crossmember sub-assembly from the vehicle body.
   

3. Remove the bolt and 2 nuts, and separate the engine mounting insulator RH.
   

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

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

   NOTICE:

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

6. 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

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

1. Remove the bolt and nut.
   

2. Remove the front engine mounting insulator from the front engine mounting bracket to remove the front crossmember sub-assembly.
   

1. Remove the 2 bolts and front engine mounting insulator.
   

1. Remove the through bolt, and separate the rear engine mounting insulator.
   

   HINT:

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

1. Remove the 4 bolts and engine mounting insulator LH.
   

   HINT:

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

HINT:

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

1. Remove the 2 bolts and radiator reservoir tank assembly.
   

   Text in Illustration 

   *A	w/ Cover
   *B	w/o Cover

HINT:

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

1. Remove the 2 bolts and 2 cooler brackets.
   

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

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

2. Remove the 2 bolts and radiator pipe.
   

1. Remove the flywheel housing side cover.
   

1. Remove the 2 bolts and starter hole insulator.
   

1. Remove the hybrid vehicle transaxle assembly (Click here).
   

   NOTICE:

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

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

   NOTICE:

   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).
   

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

   NOTICE:

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

2. Remove the flywheel sub-assembly (Click here).