Engine: Service and Repair
Removal and InstallationEM-70 Exploded View:
WARNING:
^ Place chocks at the front and back of the rear wheels.
^ For engines not equipped with slingers, attach proper slingers and bolts as described in the parts catalog.
CAUTION:
^ Do not start working until the exhaust system and coolant are cool.
^ If items or work required are not covered by the engine main body section, follow the applicable procedures.
^ Use the correct supporting points for lifting and jacking.
^ In removing the drive shaft, be careful not to damage the grease seals on the transaxle.
^ Wear electrically insulated gloves and pull out the service plug grip before inspection as procedures may require disconnecting high voltage connectors. Be sure to carry the removed service plug grip because other workers install it by mistake.
^ Never touch the high voltage connectors or terminals for 10 minutes after the service plug grip is removed.
REMOVAL
1. Release fuel pressure. Refer to EC-454, "Inspection".
Service and Repair
2. Disconnect the fuel rail at the fuel hose quick connector (engine side).
3. Drain the engine oil.
4. Drain the engine and inverter coolant.
5. Remove the engine hood assembly.
6. Drain transaxle fluid.
7. Remove engine cover using power tool.
8. Remove the air duct and air cleaner case assembly.
9. Remove the ECM bracket.
10. Remove cowl top
11. Remove strut brace.
12. Disconnect and set aside the IPDM/ER and remove the IPDM/ER bracket.
13. Remove upper and lower radiator hoses (engine side)
14. Disconnect fuel lines
15. Remove the engine coolant reservoir tank, radiator and condenser assembly.
16. Disconnect the heater hoses.
17. Remove front LR and RH wheels and tires.
18. Remove the engine under covers and splash shield using power tool.
19. Remove front exhaust tube.
20. Remove the left and right drive shafts.
21. Remove the front suspension member.
22. Remove the electric compressor.
23. Disconnect the transaxle shift controls.
24. Install engine slingers into front left cylinder head and rear right cylinder head.
^ Use the proper slingers and bolts as described in the Parts Catalog.
Slinger bolts - front: 48 Nm (4.9 kg-m, 35 ft-lb)
Slinger bolts - rear: 28 Nm (2.8 kg-m, 21 ft-lb)
25. Support engine and transaxle assembly with engine lifting equipment from the top with the vehicle raised on a hoist.
26. Remove RH engine mounting insulator and bracket.
27. Lower the engine and transaxle assembly from the engine compartment using Tool.
CAUTION:
^ Before and during this procedure, always check if any harnesses are left connected.
^ Avoid any damage to, or any oil/grease smearing or spills onto the engine mounting insulators.
Tool number: - (J-47242)
28. Separate engine and transaxle.
INSTALLATION
Installation is in the reverse order of removal after the following.
1. Be sure the grommet (1) is installed flush with the flange plane as shown prior to mating the engine and transaxle.
CAUTION:
Do not use lubricating oil for lubricant.
NOTE:
Be careful that the edge does not protrude from the socket.
EM-72 Exploded View:
^ Do not allow oil to get on mounting insulators. Be careful not to damage mounting insulators.
^ If parts have a direction mark (arrow) this indicates front of the vehicle, and the parts must be installed according to the identification mark.
INSPECTION AFTER INSTALLATION
^ Before starting the hybrid system, check oil/fluid levels including hybrid system coolant and hybrid system oil. If less than required quantity, fill to the specified level.
^ Use procedure below to check for fuel leakage.
^ Turn ignition switch ON (with hybrid system stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
^ Start the hybrid system. With engine speed increased, check again for fuel leakage at connection points.
^ Run hybrid system to check for unusual noise and vibration.
^ Warm up hybrid system thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including hybrid system oil and hybrid system coolant.
^ Bleed air from passages in lines and hoses, such as in cooling system.
^ After cooling down hybrid system, again check oils/fluids including hybrid system oil and hybrid system coolant. Refill to specified level, if necessary.
^ Summary of the inspection items:
