Removal

2ZR-FXE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

1. PRECAUTION

HINT
Service Precautions.

2. DISCHARGE FUEL SYSTEM PRESSURE

HINT
Fuel System.

3. REMOVE REAR NO. 2 FLOOR BOARD (for Separate Type) Removal

4. REMOVE REAR DECK FLOOR BOX Removal

5. REMOVE REAR NO. 3 FLOOR BOARD Removal

6. DISCONNECT CABLE FROM AUXILIARY BATTERY NEGATIVE TERMINAL

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 FRONT SPOILER COVER (w/ Front Spoiler)

13. REMOVE FRONT BUMPER LOWER ABSORBER (w/ Cover)

14. REMOVE NO. 1 ENGINE UNDER COVER

15. REMOVE NO. 2 ENGINE UNDER COVER

16. DRAIN ENGINE OIL Replacement

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

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

19. DRAIN HYBRID TRANSAXLE FLUID Procedures

20. REMOVE FRONT WIPER ARM HEAD CAP Removal

21. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal

22. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal

23. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY LH Removal

24. REMOVE COWL SIDE VENTILATOR SUB-ASSEMBLY RH Removal

25. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal

26. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Removal

27. REMOVE COWL BODY MOUNTING REINFORCEMENT LH Removal

28. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY Removal

29. 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.

30. 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.

31. REMOVE INLET AIR CLEANER ASSEMBLY

(a) Remove the 2 bolts and inlet air cleaner assembly.

32. 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.

33. REMOVE AIR CLEANER HOSE ASSEMBLY Removal

34. REMOVE RADIATOR SUPPORT OPENING COVER Removal

35. REMOVE NO. 1 INVERTER BRACKET Removal

36. DISCONNECT ENGINE ROOM MAIN WIRE Removal

37. REMOVE INVERTER TERMINAL COVER Removal

38. CHECK TERMINAL VOLTAGE Removal

39. DISCONNECT FRAME WIRE Removal

40. DISCONNECT HIGH VOLTAGE CABLE OF FRONT TRANSAXLE Removal

41. DISCONNECT NO. 2 ENGINE WIRE Removal

42. INSTALL INVERTER TERMINAL COVER Removal

43. DISCONNECT NO. 2 ENGINE ROOM WIRE Removal

44. DISCONNECT WATER HOSE Removal

45. REMOVE INVERTER WITH CONVERTER ASSEMBLY Removal

46. REMOVE INVERTER RESERVE TANK ASSEMBLY

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

47. REMOVE INVERTER TRAY BRACKET

(a) Separate the 2 clamps.

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

48. DISCONNECT NO. 1 RADIATOR HOSE

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

49. DISCONNECT NO. 2 RADIATOR HOSE

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

50. DISCONNECT NO. 4 WATER BY-PASS HOSE

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

51. DISCONNECT NO. 3 INVERTER COOLING HOSE

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

52. DISCONNECT NO. 5 INVERTER COOLING HOSE

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

53. DISCONNECT OUTLET HEATER WATER HOSE

(a) Disconnect the outlet heater water hose.

54. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose.

55. DISCONNECT HEATER HOSE

(a) Disconnect the heater hose.

56. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

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

57. 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.

58. SEPARATE COMPRESSOR WITH MOTOR ASSEMBLY Removal

59. 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.

60. SECURE STEERING WHEEL Removal

61. REMOVE COLUMN HOLE COVER SILENCER SHEET Removal

62. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

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

64. REMOVE TAIL EXHAUST PIPE ASSEMBLY Removal

65. REMOVE FRONT NO. 3 ENGINE UNDER COVER Removal

66. REMOVE FRONT CENTER FLOOR BRACE Removal

67. REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/ Exhaust Heat Recirculation System) Removal

68. REMOVE FRONT EXHAUST PIPE ASSEMBLY (w/o Exhaust Heat Recirculation System) Removal

69. REMOVE FRONT AXLE SHAFT NUT LH Removal

70. REMOVE FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

71. SEPARATE FRONT SPEED SENSOR LH Removal

72. SEPARATE FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

73. SEPARATE TIE ROD END SUB-ASSEMBLY LH Removal

74. SEPARATE TIE ROD END SUB-ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

75. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

76. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

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

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

HINT
Perform the same procedure as for the LH side.

79. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH Removal

80. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

81. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

82. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

83. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH Removal

84. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING RH

HINT
Perform the same procedure as for the LH side.

85. REMOVE FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT Removal

86. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH Removal

87. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH Removal

88. REMOVE FRONT SUSPENSION MEMBER REAR BRACE LH Removal

89. REMOVE FRONT SUSPENSION MEMBER REAR BRACE RH

HINT
Perform the same procedure as for the LH side.

90. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Removal

91. 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 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.

92. REMOVE FRONT CROSSMEMBER SUB-ASSEMBLY

(a) Remove the bolt and nut.

(b) Remove the front engine mounting insulator from the front engine mounting bracket.

93. REMOVE FRONT ENGINE MOUNTING INSULATOR

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

94. REMOVE REAR ENGINE MOUNTING INSULATOR

(a) Remove the bolt, and separate the rear engine mounting insulator.

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

95. 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.

96. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

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

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

(b) Disconnect the wire harness clamp from the engine mounting insulator sub-assembly RH.

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

97. REMOVE RADIATOR PIPE

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

(b) Remove the 2 bolts and radiator pipe.

98. REMOVE FLYWHEEL HOUSING SIDE COVER Removal

99. REMOVE STARTER HOLE INSULATOR Removal

100. REMOVE ENGINE WIRE

(a) Disconnect all the wire harnesses and connectors. Make sure that no wire harnesses are connected to the engine.

101. 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.

102. 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.

103. 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.