Removal and Installation
ENGINE ASSEMBLY
Removal and Installation
WARNING:
- Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
- Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.
- Be sure to put the removed service plug in your pocket and carry it with you so that another person does not accidentally connect it while work is in progress.
- Be sure to wear insulating protective equipment consisting of glove, shoes and glasses before beginning work on the high voltage system.
- Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or similar item to prevent other persons from contacting them.
- High Voltage Precautions.
CAUTION:
- Replace A/T assembly when separate engine and A/T assembly. Because CSC (Concentric Slave Cylinder) slides back to the original position every time when removing A/T assembly. At this timing, dust on the sliding parts may damage a seal of CSC and may cause A/T fluid leakage.
- There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do so in the Service Manual.
REMOVAL
Outline
At first, remove the engine and the transmission assembly with front suspension member downward. Then separate the engine and the transmission assembly.
Preparation
1.Release fuel pressure. Testing and Inspection.
WARNING:
Shut off high voltage circuit. How to Cut Off High Voltage.
2.Check voltage in high voltage circuit. (Check that condenser are discharged.)
a.Remove trunk finisher front. Refer toTrunk Finisher Front.
b.Remove harness cover (1).
c.Measure voltage between high voltage harness terminals.
CAUTION:
For voltage measurements, use a tester which can measure to 500 V or higher.
3.Drain engine coolant from radiator. Draining Engine Coolant.
CAUTION:
- Perform this step when engine is cold.
4.Remove the following parts:
- Radiator reservoir tank: Exploded View.
- Engine cover: Exploded View.
- Front road wheel and tires (power tool)
- Engine undercover (power tool)
- Hoodledge cover: Exploded View.
- Cowl top cover: Exploded View.
- Air duct and air cleaner case assembly (bank 1 and bank 2): Service and Repair.
- Cooling fan assembly: Exploded View.
5.Discharge refrigerant from A/C circuit. Recycle Refrigerant.
6.Remove radiator hose (upper and lower). Exploded View.
Engine Room LH
1.Disconnect heater hose from engine side, and fit a plug onto hose end to prevent coolant leak.
2.Disconnect A/C piping from electric compressor. Exploded View.
3.Disconnect ground cable.
Engine Room RH
1.Disconnect high voltage harness connector (A) from inverter, and temporarily fasten it on engine.
- For removal method of high voltage connector, refer to TMS125, "Removal and Installation".
WARNING:
- To prevent electric shock hazards, be sure to wear protective gear.
- Protect the terminals of disconnected high voltage harness connector with insulation tape so that they are not exposed.
CAUTION:
- Take care that coolant does not contact the high voltage harness connectors.
- To prevent performance degradation, if coolant contacts a high voltage harness connector, immediately dry the high voltage harness connector completely with an air blow gun.
2.Disconnect all clips and connectors of the engine room harness from engine back side.
3.Disconnect fuel feed hose (with damper) and EVAP hose. Exploded View.
CAUTION:
Fit plugs onto disconnected hoses to prevent fuel leakage.
4.Remove two eyebolts of hydraulic piping on the power steering oil pump assembly side and bracket mounting bolt. Temporarily fix the hydraulic piping on the engine side. With Heated Steering Wheel
(WITH HEATED STEERING WHEEL) or Without Heated Steering Wheel (WITHOUT HEATED STEERING
WHEEL).
Vehicle Inside
Follow procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine.
1.Remove passenger-side kicking plate and dash side finisher. Body Side Trim.
2.Disconnect engine room harness connectors at unit sides ECM and other.
3.Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine.
CAUTION:
- When pulling out harnesses, take care not to damage harnesses and connectors.
- After temporarily securing, cover connectors with vinyl or similar material to protect against foreign material adhesion.
Vehicle Underbody
1.Remove A/T oil fluid warmer hose (between A/T oil fluid warmer and heater pump).
- Install plug to avoid leakage of A/T oil fluid warmer and heater pump.
2.Disconnect heated oxygen sensor 2 harness.
3.Remove three way catalyst and exhaust front tube. Exploded View.
4.Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.
With Heated Steering Wheel (WITH HEATED STEERING WHEEL) or Without Heated Steering Wheel (WITHOUT HEATED STEERING WHEEL).
5.Remove rear propeller shaft. Exploded View.
6.Disconnect harness connector from transmission assembly.
7.Disengage A/T control rod at control device assembly side. Then, temporarily secure it on the transmission assembly, so that it does not sag. Exploded View.
8.Preparation for the separation work of transaxle is as per the following.
CAUTION:
Never separate the transmission unless otherwise needed. The transmission must be replaced if it is separated from the engine.
- Remove bolts fixing the transmission assembly to lower rear side of oil pan (upper). Exploded View.
9.Remove front stabilizer connecting rod from transverse link. Exploded View.
10.Remove lower ends of left and right steering knuckle from transverse link. Exploded View.
11.Separate steering outer sockets from steering knuckle. With Heated Steering Wheel (WITH HEATED
STEERING WHEEL) or Without Heated Steering Wheel (WITHOUT HEATED STEERING WHEEL).
12.Remove transverse links mounting bolts at suspension member side. Exploded View.
Removal Work
CAUTION:
Never separate the transmission unless otherwise needed. The transmission must be replaced if it is separated from the engine.
1.Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as a transmission jack. Securely support bottom of suspension member and transmission.
WARNING:
To prevent electric shock hazards, be sure to wear protective gear.
CAUTION:
Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
2.Remove rear engine mounting member bolts.
WARNING:
To prevent electric shock hazards, be sure to wear protective gear.
3.Remove front suspension member mounting bolts and nuts. Exploded View.
4.Carefully lower jack, or raise lift to remove the engine, transmission assembly, transfer, front final drive assembly and front suspension member. When performing work, observe the following caution and warning:
WARNING:
To prevent electric shock hazards, be sure to wear protective gear.
CAUTION:
- Confirm there is no interference with the vehicle.
- Check that all connection points have been disconnected.
- Keep in mind the center of the vehicle gravity changes. If necessary, use jack(s) to support the vehicle at rear jacking point(s) to prevent it from falling it off the lift.
Separation Work
CAUTION:
Never separate the transmission unless otherwise needed. The transmission must be replaced if it is separated from the engine.
1.Install engine slingers into front of cylinder head (bank 1) and rear of cylinder head (bank 2).
- To protect rocker cover against damage caused by tilting of engine slinger, insert spacer between cylinder head and engine rear lower slinger (3), in direction shown in the figure.
NOTE:
Spacer (2) is a component part of engine rear upper slinger assembly.
2.Remove engine mounting insulators (RH and LH) under side nuts using a power tool.
3.Lift with hoist and separate the engine and the transmission assembly from front suspension member.
CAUTION:
- Before and during this lifting, always check to see if any harnesses are left connected.
- Never damage to and oil/grease smearing or spills onto engine mounting insulator.
4.Remove crankshaft position sensor.
CAUTION:
- Handle the sensor carefully and avoid impacts to the sensor.
- Never disassemble to the sensor.
- Never place sensor in a location where it is exposed to magnetism.
5.Separate the engine from the transmission assembly. Overhaul.
6.Remove each engine mounting insulator and each engine mounting bracket from the engine using a power tool.
INSTALLATION
Note the following, and install in the reverse order of removal.
- Do not allow engine mounting insulator to be damage and careful no engine oil gets on it.
- For a location with a positioning pin, insert it securely into hole of mating part.
- For a part with a specified installation orientation, refer to component figure in Exploded View.
- When installing engine mounting bracket (RH and LH) on cylinder block, tighten two upper bolts [shown as (B) in the figure] first.
Then tighten two lower bolts [shown as (C) in the figure].
- Check all engine mounting insulators are seated properly, then tighten mounting nuts.
- Tighten rear engine mounting member bolts in numerical order as shown in the figure.
