Removal

2AZ-FXE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. PRECAUTION

HINT
Service Precautions.

2. PRECAUTION (w/ Navigation System)

NOTICE:
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, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) battery terminal.

3. DISCHARGE FUEL SYSTEM PRESSURE

HINT
Service Precautions.

4. REMOVE LUGGAGE COMPARTMENT FLOOR MAT Removal

5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Removal

6. REMOVE BATTERY SERVICE HOLE COVER Removal

7. REMOVE SERVICE PLUG GRIP Removal

8. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

9. REMOVE FRONT WHEEL

10. REMOVE REAR ENGINE UNDER COVER LH

11. REMOVE REAR ENGINE UNDER COVER RH

12. REMOVE ENGINE UNDER COVER

13. REMOVE NO. 1 ENGINE UNDER COVER

14. DRAIN ENGINE OIL Replacement

15. DRAIN COOLANT (for Engine) Coolant (for Engine)

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

17. DRAIN HYBRID TRANSAXLE FLUID Procedures

18. REMOVE FRONT WIPER ARM HEAD CAP Removal

19. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal

20. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal

21. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal

22. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Removal

23. REMOVE WATER GUARD PLATE RH Removal

24. REMOVE NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL Removal

25. REMOVE COWL BODY MOUNTING REINFORCEMENT RH Removal

26. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY Removal

27. REMOVE COOL AIR INTAKE DUCT SEAL

(a) Remove the 11 clips and cool air intake duct seal.

28. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Remove the 3 clips and No. 1 engine cover sub-assembly.

NOTICE:
* 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.

29. REMOVE CONNECTOR COVER ASSEMBLY Removal

30. CHECK TERMINAL VOLTAGE Removal

31. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY Removal

32. REMOVE NO. 5 INVERTER BRACKET Removal

33. SEPARATE GENERATOR CABLE Removal

34. SEPARATE MOTOR CABLE Removal

35. REMOVE INVERTER RESERVE TANK ASSEMBLY Removal

36. DISCONNECT WATER HOSE Removal

37. REMOVE CONNECTOR COVER ASSEMBLY Removal

38. SEPARATE AIR CONDITIONING HARNESS ASSEMBLY Removal

39. SEPARATE FRAME WIRE Removal

40. TEMPORARILY INSTALL CONNECTOR COVER ASSEMBLY Removal

41. DISCONNECT LOW VOLTAGE CONNECTOR Removal

42. REMOVE INVERTER WITH CONVERTER ASSEMBLY Removal

43. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

(a) Disconnect the clamp and air flow meter connector.

(b) Disconnect the No. 1 fuel vapor feed hose from the vacuum switching valve assembly and air cleaner hose.

(c) Disconnect the No. 2 fuel vapor feed hose from the vacuum switching valve assembly.

(d) Disconnect the clamp and vacuum switching valve connector.

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

(f) Remove the air cleaner filter element.

44. REMOVE AIR CLEANER CASE

(a) Remove the 3 bolts and air cleaner case.

45. REMOVE INVERTER BRACKET ASSEMBLY

(a) Remove the 5 bolts and inverter bracket assembly.

46. DISCONNECT NO. 3 RADIATOR HOSE

(a) Disconnect the No. 3 radiator hose.

47. DISCONNECT NO. 2 RADIATOR HOSE

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

48. DISCONNECT NO. 3 INVERTER COOLING HOSE

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

Text in Illustration

49. DISCONNECT NO. 5 INVERTER COOLING HOSE

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

50. DISCONNECT OUTLET HEATER WATER HOSE

(a) Disconnect the outlet heater water hose.

(b) Disconnect the 2 clamps from the heater hose bracket.

51. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose.

52. DISCONNECT WIRE HARNESS

(a) Pull up the lever and disconnect the connector of the hybrid vehicle control ECU.

(b) Disconnect the 3 clamps.

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

(e) Disconnect the 2 clamps.

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

(g) Remove the bolt and the bracket from the cylinder head.

(h) Remove the bolt and heater hose bracket.

53. DISCONNECT NO. 1 MOTOR COOLING HOSE Removal

54. DISCONNECT NO. 2 MOTOR COOLING HOSE Removal

55. 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 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.

56. SEPARATE ELECTRIC INVERTER COMPRESSOR

(a) Remove the bolt.

(b) Disconnect the connector (A).

Text in Illustration

(c) Release the green-colored lock.

CAUTION:
Wear insulated gloves.

(d) Disconnect the connector (B).

CAUTION:
Wear insulated gloves.

NOTICE:
Insulate the connector by sealing it with tape.

(e) Remove the bolt and 2 nuts.

(f) Using an E8 "TORX" socket, remove the 2 stud bolts and electric inverter compressor.

57. SECURE STEERING WHEEL Removal

58. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal

59. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

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

61. REMOVE FRONT NO. 3 ENGINE UNDER COVER Removal

62. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

63. REMOVE FRONT AXLE SHAFT NUT LH Removal

64. REMOVE FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

65. SEPARATE FRONT SPEED SENSOR LH Removal

66. SEPARATE FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

67. SEPARATE TIE ROD END SUB-ASSEMBLY LH Removal

68. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

69. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

70. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

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

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

HINT
Perform the same procedure as for the LH side.

73. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH Removal

74. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH Removal

75. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

76. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal

77. REMOVE FRONT DRIVE SHAFT LH HOLE SNAP RING 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 FRONT CROSS MEMBER SUB-ASSEMBLY

(a) Set the engine lifter.

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

(b) Remove the 2 bolts and separate the front engine mounting insulator from the front cross member sub-assembly.

84. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Remove the bolt and 2 nuts, and separate the engine mounting insulator sub-assembly RH.

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

(c) Carefully remove the engine assembly with transaxle from the vehicle.

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

Text in Illustration

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

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

85. REMOVE FRONT ENGINE MOUNTING INSULATOR

(a) Remove the bolt, nut and front engine mounting insulator.

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

86. REMOVE REAR NO. 1 ENGINE MOUNTING INSULATOR

(a) Remove the through bolt, and separate the rear No. 1 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. SEPARATE RADIATOR RESERVE TANK ASSEMBLY

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

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

89. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

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

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

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

90. REMOVE DRIVE SHAFT BEARING BRACKET

(a) Remove the 3 bolts and drive shaft bearing bracket.

91. REMOVE ENGINE WIRE

92. 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.

93. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

(a) Gently place the engine assembly onto wooden 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.

94. REMOVE FLYWHEEL SUB-ASSEMBLY

(a) Gently place the engine assembly onto wooden 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.

95. INSTALL ENGINE ON ENGINE STAND

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