Removal

2UR-FSE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

2. DISCHARGE FUEL SYSTEM PRESSURE Removal

3. REMOVE LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY Removal

4. REMOVE DECK TRIM SIDE BOARD LH (w/o Spare Tire) Removal

5. REMOVE BATTERY SERVICE HOLE COVER LH Removal

6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION:
Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

NOTICE:
* w/ Navigation System (for HDD):
After the power switch is turned off, the display and navigation module display (HDD navigation system) records various types of memory and settings. As a result, after turning the power switch off, be sure to wait for the time specified in the following table before disconnecting the cable from the negative (-) battery terminal.

Waiting Time before Disconnecting Cable from Negative (-) Battery Terminal:





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

7. REMOVE SERVICE PLUG GRIP

(a) Remove the service plug grip Removal.

8. REMOVE V-BANK COVER SUB-ASSEMBLY

(a) While using both hands, lift the rear side of the cover upwards to detach the 4 clips labeled B. Slide the cover towards the front of the vehicle to detach the 2 clips labeled A, and remove the V-bank cover.





NOTICE:
The V-bank cover may be damaged if its front and rear are lifted at the same time.

9. REMOVE AIR CLEANER INLET COVER SUB-ASSEMBLY

(a) Remove the 5 clips labeled A.





(b) Lift up the air cleaner inlet cover to detach the 4 clips labeled B, and remove the cover.

10. REMOVE NO. 1 AIR CLEANER INLET

(a) Remove the 2 bolts.





(b) Hold the air cleaner inlet by the protrusions labeled A and B, and detach the connections.





(c) Rotate the No. 1 air cleaner inlet as shown in the illustration to detach the protrusion labeled C.

(d) Hold the air cleaner inlet by the protrusions labeled D and E, and detach the connections.

(e) Rotate the No. 1 air cleaner inlet as shown in the illustration to detach the protrusion labeled F.

11. REMOVE ENGINE ROOM SIDE COVER RH

(a) Remove the 4 clips and side cover.





HINT
The clip labeled A cannot be removed from the cover.

NOTICE:
Remove the clip labeled A by turning it to prevent the engine room side cover RH and bracket from being damaged.

12. REMOVE ENGINE ROOM SIDE COVER LH

(a) Remove the 4 clips and side cover.





13. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

14. REMOVE COWL TOP VENTILATOR LOUVER RH Removal

15. REMOVE MOTOR CABLE COVER RH

(a) Remove the 2 clips and cable cover.





16. REMOVE INVERTER COVER ASSEMBLY RH

(a) Detach the 2 clips and remove the inverter cover.





17. REMOVE CONNECTOR COVER ASSEMBLY Removal

18. CHECK TERMINAL VOLTAGE Removal

19. INSTALL CONNECTOR COVER ASSEMBLY Components

20. REMOVE FRONT CENTER FLOOR COVER

(a) Remove the 3 screws, 2 bolts, clip and floor cover.





21. REMOVE NO. 2 ENGINE UNDER COVER

(a) Remove the 4 screws, 2 clips and under cover.





22. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH Removal

23. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH Removal

24. REMOVE NO. 1 ENGINE UNDER COVER

(a) Remove the 13 screws, 7 clips and under cover.





25. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR

(a) Remove the 9 bolts and suspension member protector.





26. DRAIN ENGINE OIL Replacement

27. DRAIN ENGINE COOLANT Service and Repair

28. DRAIN COOLANT (for Inverter) Coolant (for Inverter)

29. DRAIN FRONT DIFFERENTIAL OIL Service and Repair

30. DISCONNECT INLET OIL COOLER HOSE

(a) Using needle-nose pliers, grip the claws of the clip and slide the clip to disconnect the oil cooler hose.

HINT





Place a container under the connection before disconnecting the oil cooler hose because oil in the hose may spill out.

31. DISCONNECT OUTLET OIL COOLER HOSE

(a) Using needle-nose pliers, grip the claws of the clip and slide the clip to disconnect the oil cooler hose.





HINT
Place a container under the connection before disconnecting the oil cooler hose because oil in the hose may spill out.

32. REMOVE FRONT BUMPER COVER

(a) Remove the front bumper cover Removal.

33. REMOVE FRONT WHEELS

34. DISCONNECT FRONT FENDER LINER LH (w/ Active Stabilizer System) Removal

35. REMOVE NO. 3 COOL AIR INTAKE DUCT SUB-ASSEMBLY (w/ Active Stabilizer System) Removal

36. REMOVE INLET ENGINE ROOM ECM DUCT (w/ Active Stabilizer System) Removal

37. DISCONNECT FRONT ACTIVE STABILIZER CONTROL ACTUATOR CONNECTOR (w/ Active Stabilizer System) Removal

38. REMOVE REAR FRAME SIDE RAIL

(a) Remove the 6 bolts, 4 nuts and 2 side rails.





39. REMOVE INTAKE AIR CONNECTOR PIPE

(a) Disconnect the No. 1 ventilation hose and No. 2 ventilation hose from the intake air connector pipe.





(b) Detach the 2 clips.

(c) Loosen the 3 hose clamps, and remove the intake air connector pipe.

40. REMOVE AIR CLEANER ASSEMBLY LH Removal

41. REMOVE AIR CLEANER ASSEMBLY RH Removal

42. REMOVE RADIATOR RESERVOIR ASSEMBLY Removal

43. REMOVE OUTLET ENGINE ROOM ECM DUCT





44. REMOVE NO. 1 RADIATOR HOSE

45. REMOVE NO. 2 RADIATOR HOSE

46. REMOVE RESONATOR BRACKET SUB-ASSEMBLY Replacement

47. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY Removal

48. DISCONNECT NO. 1 FUEL HOSE Removal

49. DISCONNECT NO. 3 FUEL HOSE Removal

50. REMOVE INVERTER TERMINAL COVER Removal

51. DISCONNECT MOTOR CABLE Removal

52. DISCONNECT GENERATOR CABLE Removal

53. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

(a) Remove the bolt. Then disconnect the discharge hose.





(b) Remove the O-ring from the discharge hose.

NOTICE:
Seal the openings of the disconnected parts and motor compressor using vinyl tape and/or plastic bags to prevent moisture and foreign matter from entering them.

54. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

(a) Remove the bolt. Then disconnect the suction hose.





(b) Remove the O-ring from the suction hose.

NOTICE:
Seal the openings of the disconnected parts and motor compressor using vinyl tape and/or plastic bags to prevent moisture and foreign matter from entering them.

55. REMOVE WATER PUMP ASSEMBLY WITH MOTOR AND BRACKET Removal

56. DISCONNECT HOSES AND CONNECTORS

(a) Remove the 3 bolts and ECM box cover.





(b) Disconnect the 4 hybrid vehicle control ECU connectors and 2 wiring harness support connectors.





(c) Detach the 2 wiring harness support clips, and then detach the clip of connector A from the ECM box.

HINT
It is not necessary to disconnect the connection at A in the illustration.

(d) Lift up the wiring harness support and disconnect the 4 ECM connectors.





(e) Disconnect the heater wire connector.





(f) Disconnect the No. 5 inverter cooling hose.





(g) Disconnect the purge line hose.

(h) Disconnect the 2 heater hoses.





(i) Detach the clamp and disconnect the 3 connectors from the front controller.





(j) Remove the nut and ground wire.





(k) Disconnect the 2 oil pump motor controller connectors.

HINT
Refer to the following procedures to disconnect the oil pump driver connector Removal.

(l) Disconnect the heater water pump connector.





(m) Detach the 2 clamps. Then remove the nut and inverter cooling pipe bracket.

(n) Remove the 2 nuts, heater water pump and bracket.

(o) Disconnect the 2 connectors and detach the 5 clamps.





57. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY

(a) Remove the driver side knee airbag Removal.

58. REMOVE NO. 2 AIR DUCT SUB-ASSEMBLY

(a) Detach the 2 claws, and remove the bolt and air duct.





NOTICE:
Be careful not to damage the air duct as its connection to the vehicle is very tight.

59. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

60. REMOVE FRONT DRIVE SHAFT ASSEMBLY

(a) Remove the drive shaft Removal.

61. REMOVE FRONT EXHAUST PIPE ASSEMBLY

(a) Remove the front exhaust pipe Removal.

62. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

(a) Remove the propeller shaft Removal.

63. DISCONNECT TRANSMISSION CONTROL SHAFT LEVER

(a) Remove the nut and spring washer, and then disconnect the control shaft lever from the position sensor.





64. DISCONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY RH

(a) Remove the bolt. Then disconnect the absorber and absorber bracket.





65. DISCONNECT FRONT LOWER SHOCK ABSORBER BRACKET SUB-ASSEMBLY LH

(a) Remove the bolt. Then disconnect the absorber and absorber bracket.





66. REMOVE ENGINE AND TRANSMISSION

(a) Place a mark (with spray, etc.) over the rear right vehicle side attachment area of the front frame, which is indicated in the illustration.





(b) Place a mark (with spray, etc.) over the rear left vehicle side attachment area of the front frame.

(c) Set an engine lifter underneath the engine.

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

(d) Remove the 4 rear engine mounting member's bolts.





(e) Remove the 4 bolts shown in the illustration.





(f) Operate the engine lifter, then slowly remove the engine from the vehicle.

NOTICE:
* Make sure that the engine is clear of all wiring and hoses.
* While lowering the engine from the vehicle, do not allow it to contact the vehicle.

(g) Install 2 engine hangers with 2 bolts as shown in the illustration.





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

HINT






(h) Attach an engine sling device and hang the engine with a chain block.





NOTICE:
When hanging the engine, make sure to hang the engine with the sling device's hanging angle at 50° or less. If not, the engine or engine hangers may be damaged.

67. REMOVE FRONT FRAME ASSEMBLY

(a) Disconnect the heater wire connector and detach the 2 clips.





(b) Remove the 4 nuts and front frame.





68. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Remove the dipstick.





(b) Remove the bolt and dipstick guide.

(c) Remove the O-ring from the dipstick guide.

69. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Removal

70. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Removal

71. REMOVE FRONT ENGINE MOUNTING INSULATOR

(a) Remove the 2 nuts, 2 spacers and 2 insulators.





72. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET RH

(a) Remove the 5 bolts and mounting bracket.





73. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH

(a) Remove the 5 bolts and mounting bracket.





74. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Removal

75. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Removal

76. REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET RH

(a) Remove the 2 bolts and mounting bracket.





77. REMOVE FRONT NO. 2 ENGINE MOUNTING BRACKET LH

(a) Remove the 2 bolts and mounting bracket.





78. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

(a) Put matchmarks on the transfer companion flange and the front propeller shaft.





(b) Using a screwdriver or equivalent, hold the transfer companion flange.





(c) Using a 6 mm socket hexagon wrench, loosen the 6 bolts.

NOTICE:
Be careful not to damage the front propeller shaft.

(d) Put matchmarks on the front differential companion flange and the front propeller shaft.





(e) Using a screwdriver or equivalent, hold the differential companion flange.





(f) Using a 6 mm socket hexagon wrench, loosen the 6 bolts.

NOTICE:
Be careful not to damage the front propeller shaft.

(g) Remove the 12 bolts, 4 constant velocity universal joint washers and front propeller shaft assembly.

79. REMOVE REAR ENGINE MOUNTING MEMBER

HINT
Only perform this procedure when replacement of the engine mounting insulator is necessary.





(a) Remove the 5 nuts, No. 3 mounting insulator and mounting member.

80. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

HINT
Only perform this procedure when replacement of the engine mounting insulator is necessary.





(a) Remove the 4 bolts and 2 mounting insulators.

81. REMOVE REAR NO. 2 ENGINE MOUNTING INSULATOR

HINT
Only perform this procedure when replacement of the engine mounting insulator is necessary.





(a) Remove the 2 bolts and mounting insulator.

82. REMOVE OIL COOLER TUBE SUB-ASSEMBLY Removal

83. REMOVE OUTLET NO. 1 HYBRID WATER PUMP PIPE

(a) Remove the 2 bolts and outlet pipe.





84. REMOVE STARTER HOLE INSULATOR Removal

85. REMOVE HYBRID VEHICLE TRANSMISSION ASSEMBLY Removal

86. REMOVE INPUT TRANSMISSION DAMPER COVER ASSEMBLY

(a) Remove the 9 bolts and damper cover.





87. REMOVE FLYWHEEL SUB-ASSEMBLY

(a) Using SST, hold the crankshaft.





SST : 09213-54015

90119-08216

SST : 09330-00021

(b) Remove the 10 bolts, sensor plate and flywheel.





88. INSTALL ENGINE TO ENGINE STAND

(a) Install the engine onto an engine stand with the bolts.

(b) Remove the 2 bolts and 2 engine hangers.