Removal

2ZR-FXE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. PRECAUTION

CAUTION:
* The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.
* The vehicle has a hybrid system that operates at voltages up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this manual to handle the system correctly. Failure to do so may result in serious injury or electrocution Service Precautions.
NOTICE:
After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work Service Precautions.

2. DISCHARGE FUEL SYSTEM PRESSURE

Fuel System

3. REMOVE DECK BOARD ASSEMBLY Removal

4. REMOVE NO. 1 DECK BOARD Removal

5. REMOVE NO. 2 DECK BOARD Removal

6. REMOVE REAR DECK FLOOR BOX

7. REMOVE DECK FLOOR BOX RH

8. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL

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

9. REMOVE FRONT DECK FLOOR BOX

10. REMOVE SERVICE PLUG GRIP Removal

11. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

12. REMOVE FRONT WHEEL

13. REMOVE REAR ENGINE UNDER COVER LH

14. REMOVE REAR ENGINE UNDER COVER RH

15. REMOVE FRONT LOWER BUMPER ABSORBER

16. REMOVE NO. 1 ENGINE UNDER COVER

17. REMOVE NO. 2 ENGINE UNDER COVER

18. DRAIN ENGINE OIL Replacement

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

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

21. DRAIN HYBRID TRANSAXLE FLUID Adjustments

22. REMOVE NO. 2 CYLINDER HEAD COVER

(a) Remove the 3 clips and No. 2 cylinder head cover.

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.

23. REMOVE RADIATOR SUPPORT OPENING COVER Removal

24. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

(a) Disconnect the air flow meter connector.

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

(c) Remove the air cleaner filter element.

25. REMOVE INLET AIR CLEANER ASSEMBLY

(a) Separate the water by-pass hose from the inlet air cleaner assembly.

(b) Separate the wire harness clamp from the inlet air cleaner assembly.

(c) Remove the 3 bolts and inlet air cleaner assembly.

26. REMOVE AIR CLEANER CASE

(a) Separate the No. 4 water by-pass hose from the air cleaner case.

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

27. REMOVE AIR CLEANER HOSE ASSEMBLY Removal

28. REMOVE NO. 1 INVERTER BRACKET Removal

29. DISCONNECT ENGINE ROOM MAIN WIRE Removal

30. REMOVE INVERTER COVER Removal

31. CHECK TERMINAL VOLTAGE Removal

32. DISCONNECT FRAME WIRE Removal

33. DISCONNECT GENERATOR CABLE Removal

34. DISCONNECT MOTOR CABLE Removal

35. DISCONNECT NO. 2 ENGINE WIRE Removal

36. INSTALL INVERTER COVER Removal

37. DISCONNECT NO. 2 ENGINE ROOM WIRE Removal

38. DISCONNECT WATER HOSE Removal

39. REMOVE INVERTER WITH CONVERTER ASSEMBLY Removal

40. REMOVE INVERTER RESERVE TANK ASSEMBLY

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

41. REMOVE INVERTER TRAY BRACKET

(a) Separate the 2 clamps.

(b) Remove the 5 bolts and inverter tray bracket.

42. DISCONNECT NO. 1 RADIATOR HOSE

(a) Disconnect the No. 1 radiator hose from the radiator pipe.

43. DISCONNECT NO. 2 RADIATOR HOSE

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

44. DISCONNECT NO. 4 WATER BY-PASS HOSE

(a) Disconnect the No. 4 water by-pass hose from the radiator pipe.

45. DISCONNECT NO. 3 INVERTER COOLING HOSE

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

46. DISCONNECT NO. 5 INVERTER COOLING HOSE

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

47. DISCONNECT OUTLET HEATER WATER HOSE

(a) Disconnect the outlet heater water hose.

48. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose.

49. DISCONNECT HEATER HOSE

(a) Disconnect the heater hose.

50. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Disconnect the No. 1 fuel vapor feed hose.

51. 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.

52. SEPARATE COMPRESSOR WITH MOTOR ASSEMBLY Removal

53. DISCONNECT WIRE HARNESS

(a) Disconnect the 2 clamps.

(b) Pull up the lever and disconnect the connector of the ECM.

(c) Disconnect the 2 connectors and 2 clamps from the engine room junction block and separate the wire harness.

(d) Disconnect the 3 clamps.

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

(f) Disconnect the 2 clamps and wire harness.

54. SECURE STEERING WHEEL Removal

55. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal

56. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

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

58. REMOVE FRONT NO. 3 ENGINE UNDER COVER Removal

59. REMOVE FRONT CENTER FLOOR BRACE Removal

60. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

61. REMOVE FRONT AXLE SHAFT NUT LH Removal

62. REMOVE FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

63. SEPARATE FRONT SPEED SENSOR LH Removal

64. SEPARATE FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

65. SEPARATE TIE ROD END SUB-ASSEMBLY LH Removal

66. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

67. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

68. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

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

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

HINT
Perform the same procedure as for the LH side.

71. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH Removal

72. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

73. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

74. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

75. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH Removal

76. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING RH

HINT
Perform the same procedure as for the LH side.

77. REMOVE FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT 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 ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.

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

(b) Remove the 4 bolts and separate the front crossmember sub-assembly.

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

(e) Carefully remove the engine with transaxle from the vehicle.

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

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

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

84. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY

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

85. REMOVE FRONT ENGINE MOUNTING INSULATOR

(a) Remove the 2 bolts and front engine mounting insulator.

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

86. REMOVE REAR ENGINE MOUNTING INSULATOR

(a) Remove the through bolt, and separate the rear 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. 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.

89. REMOVE RADIATOR PIPE

(a) Separate the No. 3 radiator hose from the cylinder head.

(b) Remove the 2 bolts and radiator pipe.

90. REMOVE STARTER HOLE INSULATOR Removal

91. REMOVE FLYWHEEL HOUSING SIDE COVER Removal

92. REMOVE ENGINE WIRE

93. 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.

94. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

(a) Gently place the engine assembly onto wood 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.

95. REMOVE FLYWHEEL SUB-ASSEMBLY

(a) Gently place the engine assembly onto wood 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.