Removal

3MZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

REMOVAL

1. PRECAUTION
(a) Check for DTCs Service Precautions.
NOTE: Confirm the P0AA6 (Hybrid Battery Voltage System Isolation Fault) is not output before doing removal or installation work inside the battery. If the DTC is output, perform troubleshooting procedures first.

2. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

4. REMOVE HOOD TO COWL TOP SEAL

5. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

6. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

8. DISCHARGE FUEL SYSTEM PRESSURE
HINT:
Technician Safety Information.

9. REMOVE SERVICE PLUG GRIP Removal

10. REMOVE NO. 2 ENGINE ROOM SIDE COVER LH

(a) Remove the engine room side cover.
11. REMOVE COOL AIR INTAKE DUCT SEAL
(a) Remove the 11 clips and cool air intake duct seal.
12. REMOVE FRONT WHEELS
13. REMOVE NO. 1 ENGINE UNDER COVER
(a) Remove the 6 bolts, 2 screws, 2 clips and No. 1 engine under cover.
14. SEPARATE FRONT FENDER LINER LH
(a) Remove the screw and clip, and separate the front fender liner.
15. SEPARATE FRONT FENDER LINER RH
HINT: Perform the same procedure as above on the opposite side.

16. REMOVE FRONT FENDER APRON SEAL LH

(a) Remove the 2 bolts, clip and fender apron seal LH.
17. REMOVE FRONT FENDER APRON SEAL RH
HINT: Perform the same procedure as above on the opposite side.

18. REMOVE NO. 2 ENGINE UNDER COVER
(a) Remove the 4 bolts and No. 2 engine under cover.
19. DRAIN COOLANT (for Engine) Service and Repair

20. DRAIN COOLANT (for Inverter) Service and Repair

21. DRAIN ENGINE OIL Replacement

22. DRAIN HYBRID TRANSAXLE FLUID

23. REMOVE BATTERY
(a) Disconnect the battery terminal.
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

(b) Remove the bolt and battery clamp.
(c) Remove the battery and battery tray.
24. REMOVE BATTERY CARRIER SUB-ASSEMBLY

(a) Remove the 5 bolts and battery carrier.
25. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

(a) Remove the 2 bolts, 4 clamps and air cleaner cap sub-assembly.
(b) Remove the air cleaner filter element from the air cleaner case.
26. REMOVE AIR CLEANER CASE SUB-ASSEMBLY Removal

27. DISCONNECT NO. 1 CIRCUIT BREAKER SENSOR Removal

28. DISCONNECT NO. 2 ENGINE ROOM WIRE Removal

29. REMOVE INVERTER RESERVE TANK SUB-ASSEMBLY Removal

30. DISCONNECT WATER HOSE Removal

31. REMOVE INVERTER COVER Removal

32. CHECK TERMINAL VOLTAGE Removal

33. SEPARATE NO. 4 ENGINE WIRE Removal

34. DISCONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR Removal

35. DISCONNECT MG ECU CONNECTOR Removal

36. DISCONNECT NO. 3 FRAME WIRE Removal

37. INSTALL INVERTER COVER Removal

38. SEPARATE ENGINE ROOM RELAY BLOCK ASSEMBLY Removal

39. REMOVE NO. 4 INVERTER BRACKET Removal

40. REMOVE INVERTER WITH CONVERTER ASSEMBLY Removal

41. SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

(a) Disconnect the connector.
(b) Remove the 2 nuts and separate the brake master cylinder reservoir.
42. REMOVE AIR CLEANER BRACKET

(a) Remove the 2 bolts and air cleaner bracket.
43. REMOVE NO. 2 ENGINE MOUNTING STAY RH

(a) Remove the 2 bolts and the No. 2 engine mounting stay RH.
44. REMOVE ENGINE MOVING CONTROL ROD

(a) Remove the 2 bolts and the engine moving control rod.
45. REMOVE ENGINE MOUNTING CONTROL BRACKET

(a) Remove the 3 bolts and the engine mounting control bracket.
46. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH
47. SEPARATE COMPRESSOR WITH MOTOR ASSEMBLY
(a) Disconnect the 2 connectors.

(b) Remove the 3 bolts and compressor with motor assembly.
HINT: Disconnect the compressor assembly together with the low-pressure and high-pressure hoses, then secure it to the vehicle side with rope.

48. REMOVE NO. 1 INVERTER BRACKET

(a) Separate the 3 hose clamps.
(b) Remove the 4 bolts, harness clamp and No. 1 inverter bracket.
49. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Remove the nut and separate the control shaft lever from the position sensor.
(b) Remove the clip and disconnect the control cable from the bracket.

(c) Separate the control cable from the cable bracket.
50. DISCONNECT FUEL VAPOR FEED HOSE
51. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Remove the EFI fuel pipe clamp.

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

NOTE:
- Remove any dirt and foreign objects on the fuel tube connector before performing this work.
- Do not allow any scratches or foreign objects 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, twist or turn the nylon tube.
- Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
- If the fuel tube connector and pipe are stuck, push and pull them to release.

52. DISCONNECT INLET HEATER WATER HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the inlet heater water hose.
53. DISCONNECT OUTLET HEATER WATER HOSE
HINT: Disconnect the outlet heater water hose using the same procedure as for the heater inlet water hose.

54. DISCONNECT INLET RADIATOR HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the inlet radiator hose.
55. DISCONNECT OUTLET RADIATOR HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the outlet radiator hose.
56. DISCONNECT INLET OIL COOLER TUBE SUB-ASSEMBLY

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the inlet oil cooler tube.
57. DISCONNECT OUTLET OIL COOLER TUBE SUB-ASSEMBLY
HINT: Disconnect the outlet oil cooler tube using the same procedure as for the inlet oil cooler tube.

58. DISCONNECT WATER HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to disconnect the water hose.

(b) Using pliers, grip the claws of the clip and slide the clip to disconnect the water hose.
59. REMOVE FRONT DOOR SCUFF PLATE RH

60. REMOVE COWL SIDE TRIM SUB-ASSEMBLY RH

61. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

62. REMOVE LOWER INSTRUMENT PANEL SUB-ASSEMBLY

63. SEPARATE ENGINE WIRE

(a) Disconnect the connector and clamp from the junction block.

(b) Remove the bolt and clamp.

(e) Remove the 2 nuts and pull out the engine wire harness.

(f) Disconnect the 2 connectors.
64. REMOVE FRONT EXHAUST PIPE ASSEMBLY
(a) Disconnect the heated oxygen sensor connector.

(b) Remove the 2 bolts, 2 nuts and front exhaust pipe assembly.
(c) Remove the 2 gaskets.
65. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY
(a) Disconnect the heated oxygen sensor connector.

(b) Remove the 2 bolts, 2 nuts and front No. 3 exhaust pipe sub-assembly.
(c) Remove the 2 gaskets.
66. SECURE STEERING WHEEL

67. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

68. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.

69. REMOVE FRONT AXLE SHAFT NUT LH

70. REMOVE FRONT AXLE SHAFT NUT RH
HINT: Perform the same procedure as above on the opposite side.

71. SEPARATE FRONT SPEED SENSOR LH

72. SEPARATE FRONT SPEED SENSOR RH
HINT: Perform the same procedure as above on the opposite side.

73. SEPARATE TIE ROD END SUB-ASSEMBLY LH

74. SEPARATE TIE ROD END SUB-ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.

75. SEPARATE FRONT LOWER SUSPENSION ARM LH

76. SEPARATE FRONT LOWER SUSPENSION ARM RH
HINT: Perform the same procedure as above on the opposite side.

77. SEPARATE FRONT AXLE ASSEMBLY LH

78. SEPARATE FRONT AXLE ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.

79. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY

80. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine lifter.

(b) Remove the 6 bolts and 2 nuts, then remove the frame side plates RH and LH.

(c) Remove the 6 bolts and 2 nuts, then remove the front suspension member brace RH and LH.
(d) Carefully remove the engine assembly from the vehicle.

(e) Install the No. 2 engine hanger in the correct direction shown in the illustration.
Torque: 20 Nm (200 kgf-cm, 14 ft-lbf)
HINT: Part No. is shown in the table below.

(f) Attach the engine sling and hang the engine assembly with the chain block.
81. REMOVE ENGINE WIRE
82. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Removal

83. REMOVE MANIFOLD STAY Removal

84. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Removal

85. REMOVE HYBRID TRANSAXLE MASS DAMPER

(a) Remove the bolt and transaxle mass damper.
86. REMOVE ENGINE MOUNTING ABSORBER SUB-ASSEMBLY

(a) Remove the 2 bolts, 2 nuts and engine mounting absorber sub-assembly.
87. REMOVE REAR ENGINE MOUNTING INSULATOR

(a) Remove the 3 bolts and rear engine mounting insulator.
88. REMOVE FRONT FRAME ASSEMBLY

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

(b) Remove the 2 nuts and separate the engine mounting insulators RH and LH.
89. REMOVE FRONT ENGINE MOUNTING INSULATOR

(a) Remove the 3 nuts and front engine mounting insulator.
HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary.

90. REMOVE ENGINE MOUNTING INSULATOR LH

(a) Remove the 3 nuts and engine mounting insulator LH.
HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary.

91. REMOVE ENGINE MOUNTING INSULATOR RH

(a) Remove the 3 nuts and engine mounting insulator RH.
HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary.

92. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

93. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

94. REMOVE FLYWHEEL HOUSING UNDER COVER

95. REMOVE FRONT ENGINE MOUNTING BRACKET

96. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

97. REMOVE REAR ENGINE MOUNTING BRACKET

(a) Remove the 3 bolts and rear engine mounting bracket.
98. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY Removal

99. REMOVE FLYWHEEL SUB-ASSEMBLY Removal