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Engine: Service and Repair





ENGINE ASSEMBLY


Removal and Installation












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, refer to the applicable sections.
- Use the correct supporting points for lifting and jacking. Refer to Garage Jack And Safety Stand.
- 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 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. Remove the inverter upper LH bracket.
2. Release fuel pressure. Refer to Testing and Inspection.
3. Disconnect the 12-volt negative battery terminal.
4. Disconnect the fuel rail at the fuel hose quick connector (engine side).
5. Drain the engine oil. Refer to .
6. Drain the engine and inverter coolant. Refer to Changing Engine Coolant, Replacement.
7. Remove the engine undercover.
8. Drain transaxle fluid. Refer to Replacement.
9. Remove engine cover using power tool.
10. Remove the air duct and air cleaner case assembly. Refer to Service and Repair.
11. Remove the ECM bracket.
12. Remove cowl top. Refer to Service and Repair.
13. Remove strut brace. Refer to Exploded View.
14. Disconnect and set aside the IPDM E/R and remove the IPDM E/R bracket. Refer to Service and Repair.
15. Remove upper and lower radiator hoses (engine side).
16. Disconnect fuel lines.
17. Remove the inverter with converter assembly. Refer to Removal And Installation.
18. Disconnect the heater hoses.
19. Disconnect and set aside the brake ECU. Refer to Removal And Installation.
20. Remove front LH and RH wheels and tires. Refer to Service and Repair.





21. Remove the lower side bolt of the lower shaft assembly.
22. Remove the engine under covers and splash shield using power tool.
23. Remove front exhaust tube. Refer to Exploded View.
24. Remove the left and right drive shafts. Refer to Removal and Installation (Left Side), Removal and Installation (Right Side).
25. Disconnect the electric compressor pipes and connectors. Refer to Service and Repair.
26. Disconnect the transaxle shift controls.





27. 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.






28. Support engine and transaxle assembly with engine lifting equipment from the top with the vehicle raised on a hoist.
29. Remove the RH engine mount torque rod, RH engine support bracket, RH engine mounting insulator and
RH engine mounting bracket.
30. Remove the front suspension member bolts.
31. Lower the engine and transaxle assembly on the front suspension member 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)

32. Remove the engine and transaxle assembly from the front suspension member.
33. Separate the engine from the transaxle. Refer to Removal And Installation.

INSTALLATION
Installation is in the reverse order of removal.





- 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.
- 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.





- Install the RH engine mounting bracket bolts in the following steps:
- First install bolts (A) and (B) loosely.
- Install and tighten the five RH engine mounting bracket bolts to specification in the order as shown.

RH engine mounting bracket bolt : 48.2 N.m (4.9 kg-m, 36 ft-lb)

Arrow indicates Front

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. Refer to Maintenance.
- 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:




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