RX400h · Service Manual ENGINE

REMOVAL

Removal / installation


1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(Click here)

2. REMOVE ENGINE WIRE

3. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1

  1. A108152
    Remove the 3 bolts and exhaust manifold heat insulator No.1.


4. REMOVE MANIFOLD STAY

  1. Remove the 2 bolts and manifold stay.


5. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

  1. Disconnect the heated oxygen sensor connector.

  1. A078400E01
    Using several steps, loosen and remove the 6 nuts in the sequence shown in the illustration.

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


6. REMOVE HV TRANSAXLE MASS DAMPER

  1. A109817
    Remove the bolt and transaxle mass damper.


7. REMOVE FRONT FRAME ASSEMBLY

  1. A078403E01
    Remove the 2 nuts and separate the engine mounting insulators RH and LH.

  1. A108133
    Remove the nut and separate engine mounting insulator FR.

  1. A108134
    Remove the 2 bolts and separate the engine mounting insulator RR.


8. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

  1. C108263E01
    Using SST, remove the front drive shaft assembly LH.
    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.


9. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

  1. C108266J01
    Using pliers, remove the bearing bracket hole snap ring.

  1. C108267
    Remove the bolt from the drive shaft bearing bracket.

  1. C108268E01
    Using SST, remove the front drive shaft assembly 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.


10. REMOVE FLYWHEEL HOUSING UNDER COVER

  1. C105748
    Remove the 2 bolts and flywheel housing under cover.


11. REMOVE ENGINE MOUNTING BRACKET FRONT

  1. C105752
    Remove the 3 bolts and engine mounting bracket.


12. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

  1. C105753
    Remove the 8 bolts.

  1. 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.


13. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

  1. A109808E01
    Using SST, hold the crankshaft.
    SST
    09213-54015   (91651-60855)
    09330-00021  

  1. A108131
    Remove the 6 bolts and transmission input damper from the flywheel.


14. REMOVE FLYWHEEL SUB-ASSEMBLY

  1. A109808E01
    Using SST, hold the crankshaft.
    SST
    09213-54015   (91651-60855)
    09330-00021  

  1. A108132
    Remove the 8 bolts and flywheel.


15. INSTALL ENGINE STAND

16. REMOVE MANIFOLD CONVERTER INSULATOR NO.3

  1. A108736
    Remove the bolt, nut and manifold converter insulator No.3.


17. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2

  1. A108154
    Remove the 2 bolts and manifold heat insulator No.2.


18. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2

  1. Disconnect the heated oxygen sensor connector.

  1. A078402E01
    Using several steps, loosen and remove the 6 nuts and bolt in the sequence shown in the illustration.

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


19. REMOVE MANIFOLD STAY NO.2

  1. Remove the 2 bolts and manifold stay No.2.


20. REMOVE ENGINE MOUNTING BRACKET RH

  1. A109433
    Remove the 3 bolts and engine mounting bracket RH.


21. REMOVE ENGINE MOUNTING STAY BRACKET

  1. A109434
    Remove the bolt, nut and engine mounting stay bracket.


22. REMOVE COMPRESSOR MOUNTING BRACKET NO.1

  1. A109435
    Remove the 4 bolts and compressor mounting bracket.


23. REMOVE CRANKSHAFT PULLEY

  1. A110754E01
    Using SST, loosen the pulley bolt.
    SST
    09213-54015   (91651-60855)
    09330-00021  

  1. A110755E01
    Using SST and the pulley bolt, remove the pulley.
    SST
    09950-50013   (09951-05010, 09952-05010, 09953-05020, 09954-05031)

    NOTICE:
    Before using SST, apply lubricating oil on the threads and tip of the SST center bolt.


24. REMOVE TIMING BELT NO.1 COVER

  1. Remove the 4 bolts and the timing belt cover No.1.


25. REMOVE TIMING BELT NO.2 COVER

  1. A108158E01
    Disconnect the engine wire protector clamps from the timing belt No.2 cover.

  1. Remove the 5 bolts and the timing belt cover.


26. REMOVE ENGINE MOUNTING BRACKET RH

  1. A108728
    Remove the 2 bolts, 2 nuts and engine mounting bracket RH.


27. REMOVE TIMING BELT GUIDE NO.2

28. REMOVE TIMING BELT

  1. A078326E01
    Set No.1 cylinder to TDC/compression.

    1. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.

    2. Turn the crankshaft clockwise, and align the timing mark of the crankshaft timing pulley with the oil pump body.

    3. A005052E01
      Check that the timing marks of the camshaft timing pulleys and No.3 timing belt cover are aligned.
      If not, turn the crankshaft 1 revolution (360°).

    4. Remove the crankshaft pulley bolt.

  1. A052840E01
    If reusing the timing belt, check that there are 3 installation marks on the timing belt as shown in the illustration.

    1. If the installation marks have disappeared, put new installation marks on the timing belt before removing.

  1. A078327E01
    Set No.1 cylinder to approximately 60° BTDC/compression.

    1. Turn the crankshaft counterclockwise by approximately 60°.

      NOTICE:
      If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle.

  1. A078702E01
    Remove the timing belt tensioner.
    1st
    		 No.1 idler pulley
    2nd
    		 RH camshaft timing pulley
    3rd
    		 No.2 idler pulley
    4th
    		 LH camshaft timing pulley
    5th
    		 Water pump pulley
    6th
    		 Crankshaft timing pulley


29. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.1

  1. Using a socket hexagon wrench 10 mm, remove the pivot bolt, timing belt idler No.1 and distributor drive gear plate washer.


30. REMOVE CRANKSHAFT TIMING PULLEY

  1. Remove the bolt and the timing belt plate.

  1. A108143E01
    Install the pulley bolt to the crankshaft.

  1. Using SST, remove the crankshaft timing pulley.

    SST
    09950-50013   (09951-05010, 09952-05010, 09953-05020, 09954-05011)

    NOTICE:
    1. Do not scratch the sensor part of the crankshaft timing pulley.
    2. Before using SST, apply lubricating oil to the threads and tip of the center bolt 150.


31. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY

  1. Remove the oil level gage sub-assembly from the oil level gage guide.


32. REMOVE OIL PAN SUB-ASSEMBLY NO.2

  1. A036750
    Remove the 10 bolts and 2 nuts.

  1. A000019E02
    Insert the blade of SST between oil pan No.1 and oil pan No.2, cut off the sealer and remove the oil pan No.2.
    SST
    09032-00100  

    NOTICE:
    1. Do not damage the contact surface of oil pan No.1 where oil pan No.2 is mounted.
    2. Do not damage the flange portion of oil pan No.2 when removing.


33. REMOVE OIL STRAINER SUB-ASSEMBLY

  1. A108540
    Remove the bolt and 2 nuts, and remove the oil strainer and the gasket.


34. REMOVE OIL PAN SUB-ASSEMBLY

  1. A108539
    Loosen and remove the 17 bolts uniformly.

  1. B004137
    Using a screwdriver, remove the oil pan by prying between the cylinder block and the oil pan.

    NOTICE:
    Do not damage the contact surfaces of the oil pan and cylinder block.


35. REMOVE CRANK POSITION SENSOR

  1. Disconnect the crankshaft position sensor connector.

  1. Remove the bolt and the crankshaft position sensor.


36. REMOVE OIL PUMP ASSEMBLY

  1. A051990
    Remove the 9 bolts.

  1. Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap.

  1. A036784
    Remove the O-ring.


37. REMOVE OIL PUMP SEAL

  1. A062375
    Using a screwdriver, pry out the oil seal.

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