Engine Assembly, Removal

ENGINE ASSEMBLY

COMPONENTS:

REMOVAL
1. PRECAUTION, Refer to Vehicle Service Precautions.

2. REMOVE ENGINE ROOM SIDE LH COVER
a. Using a clip remover, remove the engine room side cover.

3. REMOVE ENGINE ROOM COVER SIDE
a. Remove the 5 clips and engine room cover side.
4. DISCHARGE FUEL SYSTEM PRESSURE
5. REMOVE SERVICE PLUG GRIP
6. REMOVE FRONT WHEELS

7. REMOVE ENGINE UNDER COVER NO. 1
a. Remove the 6 bolts, 2 screws, 2 clips and engine undercover.

8. SEPARATE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH
a. Remove the screw and separate the fender splash shield.
9. SEPARATE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

10. REMOVE FRONT FENDER APRON SEAL LH
a. Remove the 2 bolts, clip and fender apron seal LH.
11. REMOVE FRONT FENDER APRON SEAL RH

HINT: Perform the same procedure as above on the opposite side.

12. REMOVE ENGINE UNDER COVER NO. 2
a. Remove the 2 bolts and engine under cover No. 2.
13. DRAIN COOLANT (ENGINE SIDE)
14. DRAIN COOLANT (HYBRID SIDE)
15. DRAIN ENGINE OIL
16. DRAIN HYBRID TRANSAXLE FLUID
17. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH
18. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH
19. REMOVE COWL TOP VENTILATOR LOUVER SUB ASSEMBLY
20. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

21. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER
a. Separate the wire harness clamp and grommet (A).
b. Remove the 4 shock absorber nuts (B).
c. Remove the 4 bolts, 2 nuts and cowl top panel subassembly.
d. Install the 4 shock absorber nuts.
Torque: 80 Nm (815 kgf-cm, 59 ft. lbs.)
22. REMOVE BATTERY
a. Remove the bolt and battery clamp.
b. Remove the battery and battery tray.

23. REMOVE BATTERY CARRIER SUB-ASSEMBLY
a. Remove the 5 bolts and battery carrier.
24. REMOVE COOL AIR INTAKE DUCT SEAL
a. Remove the 4 clips and cool air intake duct seal.

25. REMOVE AIR CLEANER CAP W/INLET
a. Remove the 2 bolts, 4 clamps and air cleaner cap w/inlet.
b. Remove the air cleaner filter element from the air cleaner case.
26. REMOVE AIR CLEANER CASE W/RESONATOR
27. REMOVE INVERTER BRACKET NO. 5
28. REMOVE POWER STEERING ECU ASSEMBLY
29. DISCONNECT CIRCUIT BREAKER SENSOR NO. 1
30. DISCONNECT ENGINE ROOM WIRE NO. 2
31. REMOVE INVERTER RESERVE TANK SUB ASSEMBLY
32. DISCONNECT WATER HOSE
33. DISCONNECT POWER STEERING ECU BRACKET
34. REMOVE INVERTER COVER
35. REMOVE VERIFY THAT VOLTAGE OF W/CONVERTER INVERTER ASSEMBLY IS 0 V
36. REMOVE ENGINE WIRE NO. 4
37. DISCONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR
38. DISCONNECT MG ECU CONNECTOR
39. DISCONNECT NO. 3 WIRE FRAME
40. INSTALL INVERTER COVER
41. SEPARATE ENGINE ROOM RELAY BLOCK ASSEMBLY
42. REMOVE INVERTER BRACKET NO. 4
43. REMOVE W/CONVERTER INVERTER ASSEMBLY

44. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
a. Disconnect the connector.
b. Remove the 2 bolts and separate the brake master cylinder reservoir.

45. REMOVE RESERVOIR BRACKET
a. Disconnect the clamp.
b. Remove the nut, 2 bolts and reservoir bracket.

46. REMOVE AIR CLEANER BRACKET
a. Remove the 2 bolts and air cleaner bracket.
47. REMOVE ENGINE MOVING CONTROL ROD
48. REMOVE ENGINE MOUNTING STAY NO. 2 RH
49. SEPARATE COMPRESSOR W/MOTOR ASSEMBLY
a. Disconnect the 2 connectors.

b. Remove the 3 bolts and compressor w/motor assembly.

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

50. REMOVE INVERTER BRACKET NO. 1
a. Separate the 3 hose clamps.
b. Remove the 4 bolts, harness clamp and inverter bracket.

51. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY
a. Remove the nut and separate the control shaft lever from the position sensor.
b. Remove the clip and disconnect the control cable from the bracket.

c. Remove the bolt and separate the control cable from the transaxle.
52. DISCONNECT FUEL VAPOR FEED HOSE

53. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO. 1
a. Remove the EFI fuel pipe clamp.

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

NOTICE:
^ Remove any dirt and foreign objects on the fuel tube connector before performing this work.
^ 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.
^ Perform this work by hand. Do not use any tools.
^ Do not forcibly bend, twist or turn the nylon tube.
^ Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
^ If the fuel tube connector and pipe are stuck, push and pull them to release.

54. DISCONNECT HEATER WATER INLET HOSE
a. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater water inlet hose.
55. DISCONNECT HEATER WATER OUTLET HOSE

HINT: Disconnection of the heater water outlet hose is the same as for the heater water inlet hose.

56. DISCONNECT RADIATOR HOSE INLET
57. DISCONNECT RADIATOR HOSE OUTLET

58. DISCONNECT OIL COOLER INLET TUBE SUB ASSEMBLY (W/OIL COOLER)
a. Using pliers, grip the claws of the clip and slide the clip to disconnect the oil cooler inlet tube.
59. DISCONNECT OIL COOLER OUTLET TUBE SUB ASSEMBLY (W/OIL COOLER)

HINT: Disconnection of the oil cooler outlet tube is the same as for the oil cooler inlet tube.

60. REMOVE HEATER WATER PUMP ASSEMBLY
a. Disconnect the connector.

b. Remove the bolt and heater water pump.
61. DISCONNECT WATER HOSE
62. REMOVE INSTRUMENT PANEL UNDER COVER SUBASSEMBLY NO. 2
63. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY
64. SEPARATE ENGINE WIRE
a. Disconnect the engine wire harness from the ECM and the junction block.
b. Remove the 2 nuts and pull out the engine wire harness.
c. Remove the body ground and connector.
65. DISCONNECT WIRE HARNESS
a. Disconnect the power steering link connector and clamp.
b. Remove the ground cable.
66. REMOVE EXHAUST PIPE ASSEMBLY FRONT
a. Disconnect the heated oxygen sensor connector.

b. Remove the 2 bolts, 2 nuts and exhaust pipe assembly front.
c. Remove the 2 gaskets.
67. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3
a. Disconnect the heated oxygen sensor connector.

b. Remove the 2 bolts, 2 nuts and exhaust pipe sub assembly front No. 3.
c. Remove the 2 gaskets.
68. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
69. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

70. REMOVE FRONT AXLE HUB LH NUT
71. REMOVE FRONT AXLE HUB RH NUT

HINT: Perform the same procedure as above on the opposite side.

72. SEPARATE SPEED SENSOR FRONT LH
73. SEPARATE SPEED SENSOR FRONT RH

HINT: Perform the same procedure as above on the opposite side.

74. SEPARATE TIE ROD END SUB-ASSEMBLY LH
75. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

76. SEPARATE FRONT SUSPENSION ARM SUBASSEMBLY LOWER NO. 1 LH
77. SEPARATE FRONT SUSPENSION ARM SUB ASSEMBLY LOWER NO. 1 RH

HINT: Perform the same procedure as above on the opposite side.

78. SEPARATE FRONT AXLE ASSEMBLY LH
a. Using a plastic hammer, separate the drive shaft from the axle hub.

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

79. SEPARATE FRONT AXLE ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

80. SEPARATE STEERING INTERMEDIATE SHAFT SUBASSEMBLY
81. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

a. Set the engine lifter.
b. Remove the 6 bolts and 2 nuts, then remove the frame side rail plates RH and LH.

c. Remove the 6 bolts and 2 nuts, then remove the front suspension member brace rear RH and LH.
d. Carefully remove the engine assembly from the vehicle.

e. Install the No. 2 engine hanger in the correct direction shown in the illustration.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)

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

82. REMOVE ENGINE WIRE
83. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
84. REMOVE MANIFOLD STAY
85. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH

86. REMOVE HV TRANSAXLE MASS DAMPER
a. Remove the bolt and transaxle mass damper.

87. REMOVE FRONT FRAME ASSEMBLY
a. Remove the 2 nuts and separate the engine mounting insulators RH and LH.

b. Remove the nut and separate engine mounting insulator FR.

c. Remove the 2 bolts and separate the engine mounting insulator RR.
88. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
89. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
90. REMOVE FLYWHEEL HOUSING UNDER COVER
91. REMOVE ENGINE MOUNTING BRACKET FRONT
92. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY
93. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY
94. REMOVE FLYWHEEL SUB-ASSEMBLY
95. INSTALL ENGINE STAND

96. REMOVE ENGINE HANGER NO. 2
a. Remove the 2 bolts and engine hanger No. 2.
97. REMOVE EMISSION CONTROL VALVE SET
98. REMOVE INTAKE AIR SURGE TANK
99. REMOVE INTAKE MANIFOLD
100. REMOVE WATER OUTLET
101. REMOVE IGNITION COIL ASSEMBLY
102. REMOVE MANIFOLD CONVERTER INSULATOR NO. 3
103. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 2
104. REMOVE EXHAUST MANIFOLD CONVERTER SUBASSEMBLY NO. 2
105. REMOVE MANIFOLD STAY NO. 2
a. Remove the 2 bolts and manifold stay No. 2.

106. REMOVE ENGINE MOUNTING BRACKET REAR
a. Remove the 3 bolts and engine mounting bracket rear.

107. REMOVE ENGINE MOUNTING BRACKET RH
a. Remove the 3 bolts and engine mounting bracket RH.

108. REMOVE ENGINE MOUNTING STAY BRACKET
a. Remove the bolt, nut and engine mounting stay bracket.

109. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1
a. Remove the 4 bolts and compressor mounting bracket.

110. REMOVE INTAKE AIR CONNECTOR BRACKET NO. 2
a. Remove the 2 bolts and intake air connector bracket No. 2.
111. REMOVE WATER INLET PIPE
112. REMOVE WATER INLET
113. REMOVE THERMOSTAT

114. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Using a deep socket wrench 24 mm, remove the oil pressure switch.
115. REMOVE KNOCK CONTROL SENSOR
116. REPLACE PARTIAL ENGINE ASSEMBLY