REMOVAL

Wear insulation glove, and remove the service plug grip, after sliding up the lever of the service plug grip.

CAUTION:

1. Keep the removed service plug in your pocket to prevent other technicians from reconnecting it while you are servicing the vehicle.
   
2. After removing the service plug grip, do not touch the high voltage connectors and terminals for 5 minutes.
   

NOTICE:

After removing the service plug grip, do not operate the ignition switch as it may damage the hybrid vehicle control ECU.

Remove the 2 bolts and engine under cover No.2.

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.

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.

Tighten the cylinder block drain cock plugs.

Torque:

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

Remove the transaxle side reserve tank.

NOTICE:

Do not remove the reserve tank cap when the engine is hot.

Close the bleeder plug.

Install the plug with a new gasket.

Torque:

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

Remove the oil filler cap.

Remove the oil drain plug, and drain the oil into a container.

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

Torque:

45 N*m{ 459 kgf*cm , 33 ft.*lbf }

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

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

Torque:

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

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

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

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

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.

Remove the 4 shock absorber nuts (B).

Remove the 4 bolts, 2 nuts and cowl top panel sub-assembly.

Install the 4 shock absorber nuts.

Torque:

80 N*m{ 815 kgf*cm , 59 ft.*lbf }

Remove the bolt and battery clamp.

Remove the battery and battery tray.

Remove the 4 clips and cool air intake duct seal.

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

Disconnect the 2 wire harness clamps from the air cleaner.

Remove the air cleaner case w/ resonator.

Release the claw, and disconnect the engine room wire No.2.

NOTICE:

Make sure that the terminal does not stick out from the insulating tape.

Standard voltage:

0 V

HINT:

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

Disconnect the connector, clamps and grommet, and separate the engine wire No.4 from the w/ converter inverter assembly.

NOTICE:

1. 2 people are needed to remove the w/ converter inverter assembly.
   
2. If removing and storing the w/ converter inverter assembly, make sure to install the inverter cover to prevent any foreign objects or warterdrops from entering the w/ converter inverter assembly.
   
3. Attach tape or equivalent (any adhesive should not be remained) to the holes for the connectors and grommets to prevent foreign matter or water from entering.
   

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

Remove the nut, 2 bolts and reservoir bracket.

Disconnect the 2 connectors.

HINT:

Disconnect the compressor assembly together with the low-pressure and high-pressure hoses, then secure it to the vehicle side with rope.

Remove the 4 bolts, harness clamp and inverter bracket.

Remove the clip and disconnect the control cable from the bracket.

NOTICE:

1. Remove any dirt and foreign objects on the fuel tube connector before performing this work.
   
2. Do not allow any scratches or foreign objects 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, twist or turn the nylon tube.
   
5. Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
   
6. If the fuel tube connector and pipe are stuck, push and pull them to release.
   

Disconnect the connector.

HINT:

Tape the screwdriver tip before use.

Disconnect the connectors and remove the instrument panel No.2 under cover sub-assembly.

Pull the glove compartment door assembly to the rear to remove it.

Disconnect the connector.

Disconnect the engine wire harness from the ECM and the junction block.

Remove the 2 nuts and pull out the engine wire harness.

Remove the body ground and connector.

Disconnect the power steering link connector and clamp.

Remove the ground cable.

Disconnect the heated oxygen sensor connector.

Remove the 2 gaskets.

Disconnect the heated oxygen sensor connector.

Remove the 2 gaskets.

HINT:

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

SST

09930-00010  

Using a socket wrench (30 mm), remove the axle hub nut.

NOTICE:

Loosen the staked part of the nut completely, otherwise the screw of the drive shaft may be damaged.

NOTICE:

Be careful not to damage the speed sensor.

Remove the cotter pin and the nut.

SST

09628-00011  

NOTICE:

1. Hang SST with a string, etc. to prevent it from falling.
   
2. Do not damage the front disc brake dust cover.
   
3. Do not damage the ball joint dust cover.
   
4. Do not damage the steering knuckle.
   

Using a plastic hammer, separate the drive shaft from the axle hub.

NOTICE:

Be careful not to damage the boot and speed sensor rotor.

HINT:

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

Loosen the bolt (B).

HINT:

Do not remove the bolt (B).

NOTICE:

Do not separate the steering intermediate shaft sub-assembly.

Separate the steering intermediate shaft sub-assembly from the power steering link assembly.

Set the engine lifter.

Carefully remove the engine assembly from the vehicle.

Torque:

20 N*m{ 200 kgf*cm , 14 ft.*lbf }

HINT:

Part No.

No.2 engine hanger	12282-20020
Bolt	91621-60822

Attach the engine sling and hang the engine assembly with the chain block.

Remove the 2 bolts and manifold stay.

Disconnect the heated oxygen sensor connector.

Remove the exhaust manifold RH and the gasket from the cylinder head RH.

SST

09520-01010  
09520-24010   (09520-32040)

NOTICE:

1. Be careful not to damage the transaxle case oil seal and inboard joint boot.
   
2. Be careful not to drop the drive shaft assembly.
   

SST

09520-01010  
09520-24010   (09520-32040)

NOTICE:

1. Be careful not to damage the transaxle case oil seal and inboard joint boot.
   
2. Be careful not to drop the drive shaft assembly.
   

Separate and remove the hybrid vehicle transaxle.

NOTICE:

Do not pry out the connection between the transaxle assembly and engine more than necessary to prevent the knock pin from being damaged.

SST

09213-54015   (91651-60855)
09330-00021  

SST

09213-54015   (91651-60855)
09330-00021  

Remove the wire harness clamp (B).

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

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

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

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

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

Separate the fuel vapor feed hose (D).

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

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

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

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

Remove the gasket from the intake air surge tank.

Disconnect the 6 fuel injector connectors.

Disconnect the ground cable connector (A).

Remove the clamp (C).

Remove the 2 bolts, 2 nuts and 2 washers.

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

Remove the 2 gaskets from the 2 cylinder heads.

Disconnect the heated oxygen sensor connector.

Remove the exhaust manifold converter No.2 and the gasket from the cylinder head LH.

Remove the 2 bolts and manifold stay No.2.

Remove the O-ring from the water inlet pipe.

Remove the 3 nuts and the water inlet.

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