RX400h · Service Manual ENGINE

REMOVAL

Removal / installation


1. DISCHARGE FUEL SYSTEM PRESSURE
(Click here)

2. REMOVE ENGINE ROOM SIDE LH COVER

  1. A108719
    Using a clip remover, remove the engine room side cover.


3. REMOVE ENGINE ROOM COVER SIDE

  1. A109835
    Remove the 5 clips and engine room cover side.


4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

5. DRAIN COOLANT

  1. Remove the radiator cap.

    CAUTION:
    To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

  1. Drain the engine coolant by loosening the lower drain plug of the radiator and the cylinder block drain cock plugs.

    HINT:
    Engine coolant inside the radiator is drained from the drain hole located on the bottom of the engine under cover.

  1. Tighten the cylinder block drain cock plugs.

    Torque:
    13 N*m{ 133 kgf*cm , 9 in.*lbf }


    A108260E01


6. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

  1. Remove the 2 nuts and the front wiper arm and blade assembly RH.


7. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

  1. Remove the nut and the front wiper arm and blade assembly LH.


8. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

  1. E110470
    Remove the 2 clips.

  1. Disengage the 6 claws and the clamp, and remove the cowl top ventilator louver sub-assembly.


9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

  1. E110471E01
    Disconnect the connector.

  1. Remove the 5 bolts and the windshield wiper motor and link assembly.

    HINT:
    Bolt <A> cannot be removed because it is integrated into windshield wiper link assembly.


10. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER

  1. E110470
    Remove the 2 clips.

  1. Disengage the 6 claws and the clamp, and remove the cowl top ventilator louver sub-assembly.


11. REMOVE COOL AIR INTAKE DUCT SEAL

  1. Remove the 4 clips and cool air intake duct seal.


12. REMOVE AIR CLEANER CAP W/ INLET

  1. A106877E01
    Disconnect the 4 clamps.

  1. Remove the 2 bolts and air cleaner cap w/ inlet.

  1. Remove the air cleaner element from the air cleaner case.


13. REMOVE AIR CLEANER CASE W/ RESONATOR

  1. A109893
    Separate the ventilation hose No.2.

  1. A109270
    Disconnect the MAF meter connector.

  1. Disconnect the 2 wire harness clamps from the air cleaner.

  1. A106878
    Remove the 5 bolts from the air cleaner case w/ resonator.

  1. A109570
    Remove the hose clamp, and separate the air cleaner hose No.1.

  1. Remove the air cleaner case w/ resonator.


14. SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

  1. A108126
    Disconnect the connector.

  1. Remove the 2 bolts and separate the brake master cylinder reservoir.


15. REMOVE RESERVOIR BRACKET

  1. A108127
    Disconnect the clamp.

  1. Remove the nut, 2 bolts and reservoir bracket.


16. REMOVE AIR CLEANER BRACKET

  1. A108129
    Remove the 2 bolts and air cleaner bracket.


17. REMOVE ENGINE MOVING CONTROL ROD

  1. A108130
    Remove the 4 bolts, the engine moving control rod and the bracket.


18. REMOVE EMISSION CONTROL VALVE SET

  1. A109272E01
    Disconnect the VSV connector (A).

  1. Remove the wire harness clamp (B).

  1. Disconnect the fuel vapor feed hose No. 1 (C).

  1. Disconnect the fuel vapor feed hose No. 2 (D).

  1. Remove the 2 nuts (E), then remove the emission control valve set.


19. REMOVE INTAKE AIR SURGE TANK

  1. A106879E03
    Disconnect the throttle motor connector (A).

  1. Separate the water by-pass hose No. 2 (B).

  1. Separate the water by-pass hose No. 3 (C).

  1. Separate the fuel vapor feed hose (D).

  1. A109268
    Disconnect the ventilation hose.

  1. A109273E01
    Remove the 2 bolts, then remove the engine hanger No.1 (A).

  1. Remove the 2 bolts, then remove the surge tank stay No. 1 (B).

  1. Remove the 2 bolts, then remove the surge tank stay No. 2 (C).

  1. A109274E01
    Disconnect the ground cable connector.

  1. Using a socket hexagon wrench 8 mm, remove the 4 bolts.

  1. Remove the 2 nuts, then remove the emission control valve bracket and the intake air surge tank.

  1. Remove the gasket from the intake air surge tank.


20. DISCONNECT FUEL PIPE SUB-ASSEMBLY

  1. A108294E01
    Remove the EFI fuel pipe clamp No.1.

  1. Pinch the quick connector and then pull out the fuel pipe No. 1.

    NOTICE:
    1. Remove dirt or foreign objects on the quick connector before this work.
    2. Do not to allow any scratches or foreign objects on the parts when disconnecting as the fuel hose connector has the O-ring that seals the pipe.
    3. Perform this work by hand. Do not use any tools.
    4. Do not forcibly bend, twist or turn the nylon tube.
    5. Protect the connected part by covering it with a vinyl bag after disconnecting the hose.
    6. If the quick connector and pipe are stuck, push and pull them to release.


21. DISCONNECT HEATER WATER INLET HOSE

  1. A109571
    Disconnect the heater water inlet hose.


22. DISCONNECT RADIATOR HOSE INLET

  1. A108293
    Disconnect the radiator hose inlet.


23. REMOVE INTAKE MANIFOLD

  1. A109275
    Remove the nut and ground cable.

  1. A108281
    Disconnect the 6 fuel injector connectors.

  1. A108290E02
    In order to remove the intake manifold, using several steps, remove the 9 bolts and 2 nuts in the sequence shown in the illustration.


24. REMOVE WATER OUTLET

  1. Disconnect the ground cable connector (A).

  1. A108155E01
    Disconnect the engine coolant temperature sensor connector (B).

  1. Remove the clamp (C).

  1. Remove the 2 bolts, 2 nuts and 2 washers.

  1. Lock the hose clamp as shown in the illustration (D) and remove the water outlet together with water by-pass hose No.1 (E).

  1. Remove the 2 gaskets from the 2 cylinder heads.


25. REMOVE KNOCK CONTROL SENSOR

  1. A106882J01
    Disconnect the 2 knock sensor connectors.

  1. Remove the 2 nuts, and then remove the 2 knock sensors.

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