Removal [08/2019 - ]: Procedure

ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
SECURE STEERING WHEEL
Refer to PROCEDURE - Step 2
REMOVE INVERTER WITH CONVERTER ASSEMBLY
Refer to REMOVAL [08/2019 - ]
REMOVE INTAKE AIR SURGE TANK ASSEMBLY
Refer to REMOVAL [08/2019 - ]
REMOVE INVERTER TRAY BRACKET SUB-ASSEMBLY
Refer to PROCEDURE - Step 26
REMOVE BATTERY CARRIER SUB-ASSEMBLY
Refer to PROCEDURE - Step 27

REMOVE BATTERY BRACKET REINFORCEMENT

Remove the 2 bolts and battery bracket reinforcement from the vehicle body.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using a screwdriver, disengage the 4 claws and disconnect the transmission control cable assembly with the clip from the No. 1 transmission control cable bracket.

Using a screwdriver, disengage the 2 claws and remove the clip from the transmission control cable assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Disconnect the transmission control cable assembly from the No. 2 transmission control cable bracket, motor cable bracket and No. 3 transmission control cable bracket.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 2 Transmission Control Cable Bracket
*2	Motor Cable Bracket
*3	No. 3 Transmission Control Cable Bracket

DRAIN ENGINE COOLANT (for Engine)
Refer to PROCEDURE - Step 3
DISCONNECT NO. 1 RADIATOR HOSE
Refer to PROCEDURE - Step 13
REMOVE ECM ASSEMBLY
Refer to PROCEDURE - Step 8
REMOVE FRONT WHEEL OPENING EXTENSION PAD LH
Refer to PROCEDURE - Step 4
REMOVE NO. 3 ENGINE UNDER COVER
Refer to PROCEDURE - Step 5
REMOVE FRONT WHEEL OPENING EXTENSION PAD RH
Refer to PROCEDURE - Step 6
REMOVE NO. 1 ENGINE UNDER COVER
Refer to PROCEDURE - Step 7
REMOVE FRONT LOWER BUMPER ABSORBER
Refer to PROCEDURE - Step 8
REMOVE SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper)
Refer to PROCEDURE - Step 5
REMOVE NO. 2 ENGINE UNDER COVER
Refer to PROCEDURE - Step 10
REMOVE FRONT FENDER APRON SEAL LH
Refer to PROCEDURE - Step 11
REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY
Refer to PROCEDURE - Step 16
SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY
Refer to PROCEDURE - Step 5
SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
Refer to PROCEDURE - Step 6
SEPARATE FRONT STABILIZER LINK ASSEMBLY RH
HINT:

Perform the same procedure as for the LH side.
REMOVE FRONT DRIVE SHAFT ASSEMBLY
Refer to REMOVAL [10/2015 - ]
REMOVE FRONT NO. 1 STABILIZER BRACKET LH
Refer to PROCEDURE - Step 13
REMOVE FRONT NO. 1 STABILIZER BRACKET RH
HINT:

Perform the same procedure as for the LH side.
SEPARATE FRONT STABILIZER BAR
Refer to PROCEDURE - Step 15
REMOVE STEERING LINK ASSEMBLY
Refer to PROCEDURE - Step 15
REMOVE FRONT STABILIZER BAR
Refer to PROCEDURE - Step 17

REMOVE WIRE HARNESS CLAMP BRACKET

Disconnect the air fuel ratio sensor (for Bank 1) connector.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Disengage the hose clamp.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Hose Clamp
*b	Wire Harness Clamp

Disengage the 3 wire harness clamps.
Remove the bolt and wire harness clamp bracket from the engine assembly.

REMOVE FUEL PUMP PROTECTOR
Refer to PROCEDURE - Step 10

INSTALL ENGINE HANGER

Disengage the clamp.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the bolt and wire harness clamp bracket from the engine assembly.

Install the No. 1 engine hanger to the engine assembly with the bolt.

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No. 1 Engine Hanger

No. 2 Engine Hanger

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

Item	Part No.
No. 1 Engine Hanger	12281-36020
Bolt	91552-81040

Install the No. 2 engine hanger to the engine assembly with the 2 bolts.

Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf)

Item	Part No.
No. 2 Engine Hanger	12282-31100
Bolt	91671-10825

INSTALL ENGINE SUPPORT BRIDGE

Install SST to the vehicle body as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Support Shaft	*b	Front Side Member
*c	Cloth	*d	Front Side
*e	Front Suspension Nut	-	-

SST: 09940-10020

WARNING:

Make sure that no oil or grease is on the front side member, and set the support shaft on the level surface of the front side member.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Support Shaft
*b	Front Side Member

The engine support bridge may fall off if any oil or grease is still on or it is installed on the unlevel surface.

NOTE:

Prevent SST from contacting the vehicle body exterior and windshield glass.
To prevent damage to the engine hood, place pieces of cloth between the engine hood and SST.
Lightly shake SST by hand to make sure it is securely installed before performing work.

Turn the threaded portion of each support shaft to adjust its height until the sub beams are parallel to the ground.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Support Shaft
*b	Sub Beam
*c	Front Side Member
*d	Threaded Portion

Install the chain block to the sling bracket.

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*a	Chain Block	*b	Sling Bracket
*c	Fuse Shackle	*d	Shackle (A)

Install the division bar to the chain block with the shackles.

WARNING:

Make sure the fuse shackle is on the chain block side and the shackle (A) is on the division bar side as shown in the illustration so that the fuse bolt is visible and can be checked for deformation easily.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Fuse Shackle
*b	Shackle (A)

If the fuse shackle is installed upside down, deformation of the fuse bolt will not be visible and cannot be used to tell if the load capacity of the engine support bridge has been exceeded. If the load capacity is exceeded, it may cause the engine support bridge to damage the vehicle and the engine assembly with hybrid vehicle transaxle assembly may fall.

Make sure that the fuse bolt of the fuse shackle is free of damage, such as deformation or cracks. If damaged, replace the fuse shackle.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Fuse Shackle
*b	Fuse Bolt

If a deformed fuse bolt is used, it cannot be used to tell if the load capacity of the engine support bridge has been exceeded. If the load capacity is exceeded, it may cause the engine support bridge to damage the vehicle and the engine assembly with hybrid vehicle transaxle assembly may fall.

Connect the division bar to the No. 1 engine hanger with the 2 shackles (A).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 Engine Hanger	*2	No. 2 Engine Hanger
*a	Division Bar	*b	Shackle (A)
*c	Chain	-	-

Connect the division bar to the No. 2 engine hanger with the shackle (A) and chain.
NOTE:
Connect the 2nd link of the chain to the No. 2 engine hanger.

Make sure the distance between the chain block assembly and suspension ring is 120 mm (4.72 in.) or more.

HINT:

If the suspension height is less than 120 mm, adjust the links of the chain which connect the division bar and engine hanger.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	120 mm (4.72 in.) or more

Adjust the position of the support bracket LH and RH so that the length of dimension (A) and (B) are 240 mm (9.45 in.) as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Support Bracket LH	*b	Support Bracket RH
*c	Dimension (A): 240 mm (9.45 in.)	*d	Dimension (B): 240 mm (9.45 in.)
*e	Sub Beam	-	-
	Front of Vehicle	-	-

Adjust the positions of the chain block assembly, support brackets and main beam so that the chain of the chain block assembly is perpendicular to the main beam and the length of the main beam on the outer side of the support bracket LH and RH is the same as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Chain Block Assembly	*b	Main Beam
*c	Dimension (C)	*d	Dimension (D)
*e	Right to Left Adjustment	-	-

WARNING:

To prevent the engine with hybrid vehicle transaxle assembly from falling, make sure that the length of dimension (C) and dimension (D) are equal.

Do not perform any procedures if the length dimension (C) and dimension (D) are not equal.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Main Beam

Performing any procedure when the length of dimension (C) and dimension (D) are not equal may cause the engine assembly with hybrid vehicle transaxle assembly and engine support bridge to fall, possibly causing serious injury.

Confirm the appropriate installation state of the engine support bridge and tighten the 6 wing bolts and 2 bolts.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Wing Bolt

Bolt

Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

WARNING:

Do not perform any procedures before tightening the bolts to the specified torque.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Performing procedures without tightening to the bolts to the specified torque, may cause the engine support bridge to fall.

Tighten the chain block assembly until it cannot be moved any further by hand.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Turn

WARNING:

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	41 Nm (418 kgfcm, 30 ft.*lbf) or more

When suspending the engine with hybrid vehicle transaxle assembly, do not tighten the chain block assembly more than 41 N*m (418 kgf*cm, 30 ft.*lbf).
Tightening the chain block assembly more than 41 N*m (418 kgf*cm, 30 ft.*lbf) will cause the load capacity (400 kg (881.8 lb)) to be exceeded and may cause damage to the engine support bridge and vehicle body.

REMOVE ENGINE MOUNTING INSULATOR LH

Remove the bolt and disconnect the generator cable.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the bolt and nut.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the 4 bolts and engine mounting insulator LH from the hybrid vehicle transaxle assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

SEPARATE FRONT ENGINE MOUNTING INSULATOR
Refer to PROCEDURE - Step 33
SEPARATE REAR ENGINE MOUNTING INSULATOR
Refer to PROCEDURE - Step 34
REMOVE FRONT FRAME ASSEMBLY
Refer to PROCEDURE - Step 35

DISCONNECT NO. 1 MOTOR COOLING HOSE

Slide the clip and while holding the area shown in the illustration, disconnect the No. 3 motor cooling hose from the outlet oil cooler tube sub-assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	No. 1 Motor Cooling Hose
*2	No. 3 Motor Cooling Hose
*a	Hold Area
*b	Net Protector

NOTE:

Do not remove the No. 3 motor cooling hose while holding the net protector. If the No. 3 motor cooling hose is removed while holding the net protector, the No. 3 motor cooling hose may crack and hybrid transaxle fluid will leak.

Slide the clip and while holding the area shown in the illustration, disconnect the No. 1 motor cooling hose from the inlet oil cooler tube sub-assembly.
NOTE:
Do not remove the No. 1 motor cooling hose while holding the net protector. If the No. 1 motor cooling hose is removed while holding the net protector, the No. 1 motor cooling hose may crack and hybrid transaxle fluid will leak.

DISCONNECT INLET MOTOR HOSE

Slide the clip and while holding the area shown in the illustration, disconnect the outlet motor hose from the No. 3 motor cooling pipe.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Inlet Motor Hose
*2	Outlet Motor Hose
*a	Hold Area
*b	Net Protector

NOTE:

Do not remove the outlet motor hose while holding the net protector. If the outlet motor hose is removed while holding the net protector, the outlet motor hose may crack and hybrid transaxle fluid will leak.

Slide the clip and while holding the area shown in the illustration, disconnect the inlet motor hose from the No. 2 motor cooling pipe.
NOTE:
Do not remove the inlet motor hose while holding the net protector. If the inlet motor hose is removed while holding the net protector, the inlet motor hose may crack and hybrid transaxle fluid will leak.

REMOVE NO. 2 MOTOR COOLING PIPE

Remove the bolt and No. 2 oil cooler tube clamp from the oil cooler tube clamp.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Loosen the flare nut of the No. 2 motor cooling pipe and remove the No. 2 motor cooling pipe from the union.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE OIL COOLER TUBE CLAMP

Remove the bolt and oil cooler tube clamp from the hybrid vehicle transaxle assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

DISCONNECT ENGINE WIRE

Disconnect the motor resolver sensor connector.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Motor Resolver Sensor Connector	*b	Shift Lever Position Sensor Connector
*c	Generator Resolver Sensor (Generator Temperature) Connector	*d	Motor Temperature Sensor Connector

Disconnect the shift lever position sensor connector.
Disconnect the generator resolver sensor (generator temperature) connector.
Disconnect the motor temperature sensor connector.
Disengage the 8 clamps to disconnect the engine wire from the hybrid vehicle transaxle assembly.

REMOVE FRONT ENGINE MOUNTING INSULATOR

Remove the bolt and front engine mounting insulator from the front engine mounting bracket.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE REAR ENGINE MOUNTING INSULATOR

Remove the bolt and rear engine mounting insulator from the rear engine mounting bracket.

REMOVE MANIFOLD STAY

WARNING:

To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while the engine is hot.

Remove the bolt, nut and manifold stay from the rear engine mounting bracket and exhaust manifold (TWC: Front Catalyst).

REMOVE REAR ENGINE MOUNTING BRACKET

Remove the 4 bolts and rear engine mounting bracket from the hybrid vehicle transaxle assembly.

REMOVE MOTOR CABLE BRACKET

Disengage the clamp.

Remove the bolt and motor cable bracket from the hybrid vehicle transaxle assembly.

REMOVE NO. 3 AUTOMATIC TRANSMISSION CASE COVER

Disengage the clamp.

Remove the 2 bolts, clip and No. 3 automatic transmission case cover from the hybrid vehicle transaxle assembly.

REMOVE FLYWHEEL HOUSING UNDER COVER

Remove the 2 bolts and flywheel housing under cover from the hybrid vehicle transaxle assembly.

SUPPORT HYBRID VEHICLE TRANSAXLE ASSEMBLY
1. Using a transmission jack attachment, set the hybrid vehicle transaxle assembly on a transmission jack.
  NOTE:
  - Secure the hybrid vehicle transaxle assembly to the transmission jack using a suitable adapter, such as a rope or attachment.
  - To prevent the motor water jacket cover assembly from deforming, do not place any attachments under the motor water jacket cover assembly of the hybrid vehicle transaxle assembly.

REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

Remove the 10 bolts and hybrid vehicle transaxle assembly from the engine assembly.

NOTE:

To avoid damaging the knock pins, do not pry between the hybrid vehicle transaxle assembly and the engine assembly.

REMOVE FRONT ENGINE MOUNTING BRACKET

Remove the 3 bolts and front engine mounting bracket from the hybrid vehicle transaxle assembly.

REMOVE NO. 2 TRANSMISSION CONTROL CABLE BRACKET

Remove the bolt and No. 2 transmission control cable bracket from the hybrid vehicle transaxle assembly.

REMOVE WIRE HARNESS CLAMP BRACKET

Remove the bolt and wire harness clamp bracket from the hybrid vehicle transaxle assembly.

REMOVE OUTLET OIL COOLER TUBE SUB-ASSEMBLY

Remove the bolt and No. 2 oil cooler tube clamp from the No. 1 oil cooler tube clamp.

Loosen the flare nut of the outlet oil cooler tube sub-assembly and remove the outlet oil cooler tube sub-assembly from the union.

Remove the union and gasket from the hybrid vehicle transaxle assembly.

REMOVE NO. 3 MOTOR COOLING PIPE

Remove the oil cooler union bolt, gasket and No. 3 motor cooling pipe from the hybrid vehicle transaxle assembly.

REMOVE NO. 1 OIL COOLER TUBE CLAMP

Remove the bolt and No. 1 oil cooler tube clamp from the hybrid vehicle transaxle assembly.

REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET

Remove the 2 bolts and No. 1 transmission control cable bracket from the hybrid vehicle transaxle assembly.

REMOVE HV TRANSAXLE MASS DAMPER

for LH Side:

Remove the bolt and HV transaxle mass damper from the hybrid vehicle transaxle assembly.

for RH Side:

Remove the HV transaxle mass damper and gasket from the hybrid vehicle transaxle assembly.