Removal

2ZR-FXE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

CAUTION:
The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair information, or the engine lifter may suddenly drop.

1. PRECAUTION

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 information to handle the system correctly. Failure to do so may result in serious injury or electrocution Service Precautions.

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 Service Precautions.

2. DISCHARGE FUEL SYSTEM PRESSURE

Service Precautions

3. REMOVE REAR NO. 2 FLOOR BOARD Removal

4. REMOVE REAR DECK FLOOR BOX Removal

5. REMOVE REAR NO. 3 FLOOR BOARD Removal

6. REMOVE DECK FLOOR BOX RH Removal

7. REMOVE REAR FLOOR BOARD UPPER NO. 3 PLATE Removal

8. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

9. REMOVE SERVICE PLUG GRIP Removal

10. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

11. REMOVE FRONT WHEEL

12. REMOVE REAR ENGINE UNDER COVER LH

13. REMOVE REAR ENGINE UNDER COVER RH

14. REMOVE FRONT LOWER BUMPER ABSORBER

15. REMOVE NO. 1 ENGINE UNDER COVER

16. DRAIN ENGINE OIL Replacement

17. DRAIN COOLANT (for Engine) Service and Repair

18. DRAIN COOLANT (for Inverter) Service and Repair

19. DRAIN HYBRID TRANSAXLE FLUID Adjustments

20. REMOVE NO. 2 CYLINDER HEAD COVER

(a) Remove the 3 clips and No. 2 cylinder head cover.

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

21. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

(a) Disconnect the air flow meter connector.

(b) Separate the water by-pass hose from the air cleaner cap sub-assembly.

(c) Disconnect the 2 clamps and hose band, and remove the air cleaner cap sub-assembly.

(d) Remove the air cleaner filter element.

22. REMOVE INLET AIR CLEANER

(a) Separate the water by-pass hose from the inlet air cleaner.

(b) Separate the wire harness clamp from the inlet air cleaner.

(c) Remove the 2 bolts, 2 clips and inlet air cleaner.

23. REMOVE AIR CLEANER CASE

(a) Separate the No. 4 water by-pass hose from the air cleaner case.

(b) Disconnect the wire harness clamp from the air cleaner case.

(c) Remove the 2 bolts and air cleaner case.

24. REMOVE AIR CLEANER HOSE ASSEMBLY Removal

25. REMOVE RADIATOR SUPPORT OPENING COVER Removal

26. REMOVE INVERTER COVER ASSEMBLY LH (w/ Cover) Removal

27. REMOVE NO. 1 INVERTER BRACKET Removal

28. DISCONNECT ENGINE ROOM MAIN WIRE Removal

29. REMOVE INVERTER COVER Removal

30. CHECK TERMINAL VOLTAGE Removal

31. DISCONNECT FRAME WIRE Removal

32. DISCONNECT GENERATOR CABLE Removal

33. DISCONNECT MOTOR CABLE Removal

34. DISCONNECT NO. 2 ENGINE WIRE Removal

35. INSTALL INVERTER COVER Removal

36. DISCONNECT NO. 2 ENGINE ROOM WIRE Removal

37. DISCONNECT WATER HOSE Removal

38. REMOVE INVERTER WITH CONVERTER ASSEMBLY Removal

39. REMOVE INVERTER RESERVE TANK ASSEMBLY

(a) Remove the 2 bolts and separate the inverter reserve tank assembly.

40. REMOVE INVERTER TRAY BRACKET

(a) Separate the 2 clamps.

(b) Remove the 5 bolts and inverter tray bracket.

41. DISCONNECT NO. 1 RADIATOR HOSE

(a) Disconnect the No. 1 radiator hose from the radiator pipe assembly.

42. DISCONNECT NO. 2 RADIATOR HOSE

(a) Disconnect the No. 2 radiator hose from the water inlet.

43. DISCONNECT NO. 4 WATER BY-PASS HOSE

(a) Disconnect the No. 4 water by-pass hose from the radiator pipe assembly.

44. DISCONNECT NO. 3 INVERTER COOLING HOSE

(a) Disconnect the No. 3 inverter cooling hose from the hybrid transaxle assembly.

Text in Illustration

45. DISCONNECT NO. 5 INVERTER COOLING HOSE

(a) Disconnect the No. 5 inverter cooling hose from the hybrid transaxle assembly.

46. DISCONNECT OUTLET HEATER WATER HOSE

(a) Disconnect the outlet heater water hose.

47. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose.

48. DISCONNECT HEATER HOSE

(a) Disconnect the heater hose.

49. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

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

50. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Release the claw and remove the No. 1 fuel pipe clamp.

(b) Pinch the retainer as illustrated, then pull the fuel tube connector out of the pipe.

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

51. SEPARATE ELECTRIC INVERTER COMPRESSOR Removal

52. DISCONNECT WIRE HARNESS

(a) Disconnect the 2 clamps.

(b) Pull up the lever and disconnect the connector of the ECM.

(c) Disconnect the 2 connectors and 2 clamps from the engine room junction block and separate the wire harness.

(d) Disconnect the 2 clamps.

(e) Remove the bolt and disconnect the earth wire.

(f) Disconnect the 2 clamps and wire harness.

53. SECURE STEERING WHEEL Removal

54. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal

55. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

56. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Removal

57. REMOVE FRONT NO. 3 ENGINE UNDER COVER Removal

58. REMOVE FRONT CENTER FLOOR BRACE Removal

59. REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/ Exhaust Heat Recirculation System) Removal

60. REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/o Exhaust Heat Recirculation System) Removal

61. REMOVE FRONT AXLE SHAFT NUT LH Removal

62. REMOVE FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

63. SEPARATE FRONT SPEED SENSOR LH Removal

64. SEPARATE FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

65. SEPARATE TIE ROD END SUB-ASSEMBLY LH Removal

66. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

67. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

68. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

69. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH Removal

70. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

71. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH Removal

72. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

73. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

74. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

75. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH Removal

76. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING RH

HINT
Perform the same procedure as for the LH side.

77. REMOVE FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT Removal

78. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH Removal

79. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH Removal

80. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH Removal

81. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

HINT
Perform the same procedure as for the LH side.

82. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Removal

83. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.

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

(b) Remove the 4 bolts to separate the front crossmember sub-assembly from the vehicle body.

(d) Remove the bolt and nut, and separate the engine mounting insulator LH.

(e) Carefully remove the engine with transaxle from the vehicle.

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

(f) Install the 2 engine hangers with the 2 bolts.

Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

(g) Attach the sling device to the engine hangers and chain block.

84. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY

(a) Remove the bolt and nut.

(b) Remove the front engine mounting insulator from the front engine mounting bracket to remove the front crossmember sub-assembly.

85. REMOVE FRONT ENGINE MOUNTING INSULATOR

(a) Remove the 2 bolts and front engine mounting insulator.

86. REMOVE REAR ENGINE MOUNTING INSULATOR

(a) 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.

87. REMOVE ENGINE MOUNTING INSULATOR LH

(a) Remove the 4 bolts and engine mounting insulator LH.

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

88. REMOVE RADIATOR RESERVOIR TANK ASSEMBLY

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

(a) Remove the 2 bolts and radiator reservoir tank assembly.

Text in Illustration

89. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

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

(a) Remove the 2 bolts and 2 cooler brackets.

(b) Remove the 3 bolts and engine mounting insulator sub-assembly RH.

90. REMOVE RADIATOR PIPE

(a) Separate the No. 3 radiator hose from the cylinder head.

(b) Remove the 2 bolts and radiator pipe.

91. REMOVE FLYWHEEL HOUSING SIDE COVER Removal

92. REMOVE STARTER HOLE INSULATOR Removal

93. REMOVE ENGINE WIRE

94. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

(a) Remove the hybrid vehicle transaxle assembly Removal.

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.

95. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

(a) 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.

(b) Remove the transmission input damper assembly Removal.

96. REMOVE FLYWHEEL SUB-ASSEMBLY

(a) 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.

(b) Remove the flywheel sub-assembly Removal.