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Removal [08/2020 - 08/2021]: Procedure

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  1. PRECAUTION 
    NOTE:

    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.

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  3. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [08/2020 - ]

  4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  5. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 3

  6. REMOVE FRONT WHEELS 

    Refer to REMOVAL [06/2018 - ]

  7. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 
    1. Remove the 3 screws and front wheel opening extension pad LH.
  8. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 
    1. Remove the 3 screws and front wheel opening extension pad RH.
  9. REMOVE NO. 1 ENGINE UNDER COVER 
    1. Remove the bolt, 2 clips, 6 screws and No. 1 engine under cover.
  10. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY 
    1. Remove the 4 screws, 6 clips and No. 2 engine under cover assembly.
  11. REMOVE FRONT FENDER APRON SEAL LH 
    1. Remove the 2 screws, clip and front fender apron seal LH.
  12. REMOVE FRONT FENDER APRON SEAL RH 
    1. Remove the 2 screws, clip and front fender apron seal RH.
  13. REMOVE HEADLIGHT ASSEMBLY 
  14. REMOVE FRONT LOWER BUMPER ABSORBER 
    1. Remove the 4 bolts.
      GTY804224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 claws to remove the front lower bumper absorber.
  15. DRAIN ENGINE COOLANT 

    Refer to PROCEDURE - Step 1

  16. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 2

  17. DRAIN HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 5

  18. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Lift the front of the No. 1 engine cover sub-assembly to disengage the clip, and then lift the rear of the No. 1 engine cover sub-assembly to disengage the 3 clips and remove the No. 1 engine cover sub-assembly.
      NOTE:

      Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover sub-assembly to break.

      GTY799932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to REMOVAL [08/2020 - 08/2021]

  20. REMOVE INVERTER RESERVE TANK ASSEMBLY 
    1. Remove the bolt.
      GTY762036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 5 Inverter Cooling Hose
      *2 No. 2 Inverter Cooling Hose
      *a Pin
      *b Grommet
    2. Disengage the pin and remove the inverter reserve tank assembly.
    3. Slide the clip and disconnect the No. 5 inverter cooling hose from the inverter reserve tank assembly.
    4. Slide the clip and disconnect the No. 2 inverter cooling hose from the inverter reserve tank assembly.
  21. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Slide the clip and disconnect the No. 1 fuel vapor feed hose from the No. 1 vacuum switching valve assembly.
      GTY773130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT OUTLET HEATER HOSE 
    1. Pull out the retainer to disengage the lock claws and pull off the outlet heater hose from the No. 2 water by-pass pipe sub-assembly.
      GTY744415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Pull out
      Pull off
    2. Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.
    3. Cover the disconnected No. 2 water by-pass pipe sub-assembly and outlet heater hose connector with plastic bags to prevent damage and contamination.
  23. DISCONNECT INLET HEATER HOSE 
    1. Pull out the retainer to disengage the lock claws and pull off the inlet heater hose from the flow shutting valve (water by-pass hose assembly).
      GTY746391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Pull out
      Pull off
    2. Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.
    3. Cover the disconnected flow shutting valve (water by-pass hose assembly) and inlet heater hose connector with plastic bags to prevent damage and contamination.
  24. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the EFI fuel pipe clamp from the fuel tube connector.
      GTY761413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tube sub-assembly.
      1. Disconnect the fuel tube sub-assembly from the fuel pipe.
        GTY761414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Refer to PRECAUTION [08/2020 - ]

  25. REMOVE NO. 2 ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 4

  26. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 1 radiator hose from the water outlet.
      GTY766728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt to disconnect the No. 1 radiator hose from the front engine mounting bracket.
  27. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.
      GTY761404Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 6

  29. DISCONNECT SUCTION HOSE 

    Refer to PROCEDURE - Step 5

  30. DISCONNECT NO. 5 INVERTER COOLING HOSE 
    1. Slide the clip and disconnect the No. 5 inverter cooling hose from the motor cooling cooler.
      GTY768594Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. DISCONNECT WIRE HARNESS 

    HINT: 

    After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way.

    1. Remove the No. 2 relay block cover from the engine room relay block and junction block assembly.
      GTY761410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut from the engine room relay block and junction block assembly.
      GTY773129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the 5 connectors from the engine room relay block and junction block assembly.
    4. Using a screwdriver, disengage the claw and disconnect the wire harness from the engine room relay block and junction block assembly.
    5. Remove the 2 bolts and disengage the earth wire.
      GTY761408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. DISCONNECT NO. 5 WATER BY-PASS HOSE 
    1. Slide the clip and disconnect the No. 5 water by-pass hose from the No. 3 water by-pass pipe.
      GTY761409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 11

  34. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 

    Refer to REMOVAL [06/2018 - ]

  35. REMOVE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to REMOVAL [06/2018 - ]

  36. REMOVE SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper) 

    Refer to PROCEDURE - Step 4

  37. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on an engine lifter.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle level.
      • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
      • To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.
    2. Remove the 6 bolts and body mounting plate.
      GTY773128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 bolts and nut and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.
      GTY787653Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 3 bolts and remove the engine mounting stay LH from the engine mounting insulator LH.
      GTY761406Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 bolts and separate the engine mounting insulator LH from the hybrid vehicle transaxle assembly.
      GTY761398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. w/o Suspension Tower Damper:
      1. Remove the 4 bolts (A), 2 bolts (B) and 2 bolts (C) and front bumper extension sub-assembly RH and front bumper extension sub-assembly LH from the front frame assembly and vehicle body.
        GTY760675Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut
      2. Remove the 2 bolts (D), 2 bolts (E) and 2 nuts and front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH from the front frame assembly and vehicle body.
    7. w/ Suspension Tower Damper:
      1. Remove the 2 bolts (A), 2 bolts (B) and 2 bolts (C) and front bumper extension sub-assembly RH and front bumper extension sub-assembly LH from the front frame assembly and vehicle body.
        GTY814829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Bolt
        Nut
      2. Remove the 2 bolts (D), 2 bolts (E) and 2 nuts and front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH from the front frame assembly and vehicle body.
    8. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.
      NOTE:
      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
      • While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.
  38. REMOVE FUEL DELIVERY GUARD 
    1. Remove the bolt and fuel delivery guard from the engine mounting bracket RH.
      GTY761402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. INSTALL ENGINE HANGERS 
    1. Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.
      GTY769283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Torque: 43 N.m (438 kgf/cm, 32 ft.lbf) 

      HINT: 

      No. 1 Engine Hanger 12281-25030
      No. 2 Engine Hanger 12282-25010
      Bolt 90105-A0354
    2. Using an engine sling device and engine lift, secure the engine assembly with transaxle.
      NOTE:
      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.
      • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
  40. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the flywheel housing under cover from the cylinder block sub-assembly.
      GTY753666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE STEERING GEAR HEAT INSULATOR 

    Refer to PROCEDURE - Step 15

  42. REMOVE ENGINE WIRE 
    1. Disconnect all clamps and connectors and remove the engine wire from the engine assembly with transaxle.
  43. REMOVE FRONT FRAME ASSEMBLY 

    Refer to PROCEDURE - Step 7

  44. REMOVE FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    Refer to PROCEDURE - Step 11

  45. REMOVE REAR ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Remove the bolt and rear engine mounting insulator from the rear engine mounting bracket.
      GTY774292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE HV AIR CONDITIONING WIRE 
    1. Disengage the 2 clamps.
      GTY768590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the connector.
      GTY743434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Green-colored Lock
      Slide
      WARNING:

      Make sure to wear insulated gloves.

      NOTE:

      Insulate the disconnected terminals and connector with insulating tape.

    3. Remove the bolt.
      GTY747656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the guide to remove the HV air conditioning wire from the hybrid vehicle transaxle assembly.
  47. REMOVE STARTER HOLE INSULATOR 

    Refer to PROCEDURE - Step 8

  48. REMOVE FLYWHEEL HOUSING SIDE COVER 

    Refer to PROCEDURE - Step 9

  49. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 15

  50. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY 

    See step  2

  51. REMOVE FLYWHEEL SUB-ASSEMBLY 

    See step  3

  52. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 

    See step  4

  53. INSTALL ENGINE ASSEMBLY TO ENGINE STAND 
    1. Install the engine assembly to an engine stand.
  54. REMOVE ENGINE HANGERS 
    1. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and engine mounting bracket RH.
  55. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

    1. Disengage the No. 6 water by-pass hose.
      GTY761400Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, nut and the radiator reserve tank assembly.
    3. Remove the bolt and disconnect the No. 2 earth wire from the engine mounting insulator sub-assembly RH.
      GTY781244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the clamp.
      GTY787654Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt and disconnect the cooler bracket from the engine mounting insulator sub-assembly RH.
    6. Remove the 2 bolts and nut and remove the engine mounting insulator sub-assembly RH.
  56. REMOVE ENGINE MOUNTING SPACER 

    HINT: 

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

    1. Remove the 2 bolts and engine mounting spacer from the vehicle body.
      GTY773126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE ENGINE MOUNTING INSULATOR LH 

    HINT: 

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

    1. Remove the 2 bolts, nut and the engine mounting insulator LH.
      GTY761399Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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