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Engine Assembly: Removal

  1. PRECAUTION 

    (See PRECAUTION )

  2. REMOVE ENGINE ROOM SIDE LH COVER NO.2 
    1. Using a clip remover, remove the engine room side cover.
      Fig 1: Identifying Engine Room Side LH Cover
      G05200470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. DISCHARGE FUEL SYSTEM PRESSURE 

    (See FUEL SYSTEM )

  4. REMOVE SERVICE PLUG GRIP  (See REMOVAL )
  5. REMOVE FRONT WHEELS 
  6. REMOVE ENGINE UNDER COVER NO.1 
    1. Remove the 6 bolts, 2 screws, 2 clips and engine under cover.
      Fig 2: Locating Clips, Engine Under Cover And Bolts, Screws
      G05200471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. SEPARATE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH 
    1. Remove the screw and clip, and separate the fender splash shield.
  8. SEPARATE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

    Fig 3: Locating Fender Splash Shield With Screw And Clip
    G05200472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FRONT FENDER APRON SEAL LH 
    1. Remove the 2 bolts, clip and fender apron seal LH.
      Fig 4: Locating Bolts, Clip And Fender Apron Seal LH
      G05200473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FRONT FENDER APRON SEAL RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  11. REMOVE ENGINE UNDER COVER NO.2 
    1. Remove the 2 bolts and engine under cover No.2.
  12. DRAIN COOLANT (Engine side)  (See COOLANT )
  13. DRAIN COOLANT (Hybrid side)  (See COOLANT )
  14. DRAIN ENGINE OIL  (See OIL AND OIL FILTER )
  15. DRAIN HYBRID TRANSAXLE FLUID  (See HYBRID TRANSAXLE FLUID )
  16. REMOVE FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER 
    1. Remove the 4 nuts and front suspension brace sub-assembly.
      Fig 5: Identifying Front Suspension Brace Sub-Assembly Upper Center And Nuts
      G05200474Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the 4 shock absorber nuts.

      Torque: 80 N*m (815 kgf*cm, 59 ft.*lbf) 

  17. REMOVE BATTERY 
    1. Remove the bolt and battery clamp.
    2. Remove the battery and battery tray.
  18. REMOVE BATTERY CARRIER SUB-ASSEMBLY 
    1. Remove the 5 bolts and battery carrier.
      Fig 6: Locating Bolts And Battery Carrier
      G05200475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE AIR CLEANER CAP W7 INLET 
    1. Remove the 2 bolts, 4 clamps and air cleaner cap w/ inlet.
      Fig 7: Locating Bolts, Clamps And Air Cleaner Cap W/Inlet
      G05200225Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the air cleaner filter element from the air cleaner case.
  20. REMOVE AIR CLEANER CASE W/ RESONATOR  (See REMOVAL )
  21. REMOVE INVERTER BRACKET NO.5  (See REMOVAL )
  22. REMOVE POWER STEERING ECU ASSEMBLY  (See REMOVAL )
  23. DISCONNECT CIRCUIT BREAKER SENSOR NO.1  (See REMOVAL )
  24. DISCONNECT ENGINE ROOM WIRE NO.2  (See REMOVAL )
  25. REMOVE INVERTER RESERVE TANK SUB-ASSEMBLY  (See REMOVAL )
  26. DISCONNECT WATER HOSE  (See REMOVAL )
  27. REMOVE POWER STEERING ECU BRACKET  (See REMOVAL )
  28. REMOVE INVERTER COVER  (See REMOVAL )
  29. VERIFY THAT VOLTAGE OF W/CONVERTER INVERTER ASSEMBLY IS 0V  (See REMOVAL )
  30. SEPARATE ENGINE WIRE NO.4  (See REMOVAL )
  31. DISCONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR  (See REMOVAL )
  32. DISCONNECT MG ECU CONNECTOR  (See REMOVAL )
  33. DISCONNECT NO.3 WIRE FRAME  (See REMOVAL )
  34. INSTALL INVERTER COVER  (See REMOVAL )
  35. SEPARATE ENGINE ROOM RELAY BLOCK ASSEMBLY  (See REMOVAL )
  36. REMOVE INVERTER BRACKET NO.4  (See INSTALLATION )
  37. REMOVE W/ CONVERTER INVERTER ASSEMBLY  (See INSTALLATION )
  38. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY 
    1. Disconnect the connector.
    2. Remove the 2 bolts and separate the brake master cylinder reservoir.
      Fig 8: Locating Bolts And Brake Master Cylinder Reservoir To Bracket
      G05200477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE RESERVOIR BRACKET 
    1. Disconnect the clamp.
    2. Remove the nut, 2 bolts and reservoir bracket.
      Fig 9: Locating Bolts, Nut And Reservoir Bracket
      G05200478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE AIR CLEANER BRACKET 
    1. Remove the 2 bolts and air cleaner bracket.
      Fig 10: Locating Bolts And Air Cleaner Bracket
      G05200479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE ENGINE MOVING CONTROL ROD (See  REMOVAL   ) 
  42. REMOVE ENGINE MOUNTING STAY NO.2 RH (See  REMOVAL   ) 
  43. SEPARATE COMPRESSOR W/ MOTOR ASSEMBLY 
    1. Disconnect the 2 connectors.
    2. Remove the 3 bolts and compressor w/ motor assembly.

      HINT:

      Disconnect the compressor assembly together with the low-pressure and high-pressure hoses, then secure it to the vehicle side with rope.

      Fig 11: Locating Bolts And Compressor W/ Motor Assembly
      G05200480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE INVERTER BRACKET NO.1 
    1. Separate the 3 hose clamps.
    2. Remove the 4 bolts, harness clamp and inverter bracket.
      Fig 12: Locating Bolts And Inverter Bracket
      G05200481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the nut and separate the control shaft lever from the position sensor.
    2. Remove the clip and disconnect the control cable from the bracket.
      Fig 13: Locating Control Cable And New Clip To Bracket
      G05200482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and separate the control cable from the transaxle.
      Fig 14: Locating Control Cable To Transaxle With Bolt
      G05200483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. DISCONNECT FUEL VAPOR FEED HOSE 
  47. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO.1 
    1. Remove the EFI fuel pipe clamp.
      Fig 15: Removing EFI Fuel Pipe Clamp
      G05200484Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch the retainer as illustrated, then pull out the fuel tube connector from the pipe.
      NOTE:
      • Remove any dirt and foreign objects on the fuel tube connector before performing this work.
      • Do not allow any scratches or foreign objects 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.
        Fig 16: Identifying Tube Connector
        G05200485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • Do not forcibly bend, twist or turn the nylon tube.
      • Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
      • If the fuel tube connector and pipe are stuck, push and pull them to release.
  48. DISCONNECT HEATER WATER INLET HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater water inlet hose.
  49. DISCONNECT HEATER WATER OUTLET HOSE 

    HINT:

    Disconnection of the heater water outlet hose is the same as for the heater water inlet hose.

    Fig 17: Locating Heater Water Outlet Hose
    G05200486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. DISCONNECT RADIATOR HOSE INLET 
  51. DISCONNECT RADIATOR HOSE OUTLET 
  52. DISCONNECT OIL COOLER INLET TUBE SUB-ASSEMBLY (W/ OIL COOLER) 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the oil cooler inlet tube.
      Fig 18: Locating Oil Cooler Inlet Tube Sub-Assembly (W/ Oil Cooler)
      G05200487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. DISCONNECT OIL COOLER OUTLET TUBE SUB-ASSEMBLY (W/ OIL COOLER) 

    HINT:

    Disconnection of the oil cooler outlet tube is the same as for the oil cooler inlet tube.

  54. REMOVE HEATER WATER PUMP ASSEMBLY 
    1. Disconnect the connector.
    2. Remove the bolt and heater water pump.
      Fig 19: Locating Bolt And Heater Water Pump Assembly
      G05200488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. DISCONNECT WATER HOSE 
  56. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY  (See REMOVAL )
  57. SEPARATE ENGINE WIRE 
    1. Disconnect the engine wire harness from the ECM and the junction block.
    2. Remove the 2 nuts and pull out the engine wire harness.
    3. Remove the body ground and connector.
  58. DISCONNECT WIRE HARNESS 
    1. Disconnect the power steering link connector and clamp.
    2. Remove the ground cable.
  59. REMOVE EXHAUST PIPE ASSEMBLY FRONT 
    1. Disconnect the heated oxygen sensor connector.
    2. Remove the 2 bolts, 2 nuts and exhaust pipe assembly front.
      Fig 20: Locating Gaskets And Exhaust Pipe Front, Bolts Nuts
      G05200489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 gaskets.
  60. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO.3 
    1. Disconnect the heated oxygen sensor connector.
    2. Remove the 2 bolts, 2 nuts and exhaust pipe sub-assembly front No.3.
      Fig 21: Locating Gaskets And Exhaust Pipe Front With Bolts And Nuts
      G05200490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 gaskets.
  61. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH  (See REMOVAL )
  62. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  63. REMOVE FRONT AXLE SHAFT LH NUT  (See REMOVAL )
  64. REMOVE FRONT AXLE SHAFT RH NUT 

    HINT:

    Perform the same procedure as above on the opposite side.

  65. SEPARATE SPEED SENSOR FRONT LH  (See REMOVAL )
  66. SEPARATE SPEED SENSOR FRONT RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  67. SEPARATE TIE ROD END SUB-ASSEMBLY LH  (See DISASSEMBLY )
  68. SEPARATE TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  69. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH  (See REMOVAL )
  70. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  71. SEPARATE FRONT AXLE ASSEMBLY LH 
    1. Using a plastic hammer, separate the drive shaft from the axle hub.
      NOTE: Be careful not to damage the boot and speed sensor rotor.
  72. SEPARATE FRONT AXLE ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  73. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY  (See REMOVAL )
  74. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
    2. Remove the 6 bolts and 2 nuts, then remove the frame side rail plates RH and LH.
      Fig 22: Locating Bolts And Nuts, Frame Side Rail Plates RH And LH
      G05200491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 bolts and 2 nuts, then remove the front suspension member brace rear RH and LH.
    4. Carefully remove the engine assembly from the vehicle.
      Fig 23: Locating Bolts And Nuts, Front Suspension Member Brace Rear RH And LH
      G05200492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the No.2 engine hanger in the correct direction shown in the illustration.

      Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

      HINT:

      Part No.

      TORQUE SPECIFICATION

      No.2 engine hanger 12282-20020
      Bolt 91621-60822
    6. Attach the engine sling and hang the engine assembly with the chain block.
      Fig 24: Identifying Engine Hanger
      G05200493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE ENGINE WIRE 
  76. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See  REMOVAL   ) 
  77. REMOVE MANIFOLD STAY (See  REMOVAL   ) 
  78. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (See  REMOVAL   ) 
  79. REMOVE HV TRANSAXLE MASS DAMPER 
    1. Remove the bolt and transaxle mass damper.
      Fig 25: Locating Transaxle Mass Damper And Bolts
      G05200494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. REMOVE FRONT FRAME ASSEMBLY 
    1. Remove the 2 nuts and separate the engine mounting insulators RH and LH.
      Fig 26: Locating Engine Mounting Insulator RH And LH With Nuts
      G05129362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut and separate engine mounting insulator FR.
      Fig 27: Locating Engine Mounting Insulator FR With Nut
      G05200496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and separate the engine mounting insulator RR.
      Fig 28: Locating Engine Mounting Insulator RR With Bolts
      G05200497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH  (See REMOVAL )
  82. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH  (See REMOVAL )
  83. REMOVE FLYWHEEL HOUSING UNDER COVER  (See REMOVAL )
  84. REMOVE ENGINE MOUNTING BRACKET FRONT  (See REMOVAL )
  85. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY  (See REMOVAL )
  86. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY (See  REMOVAL   ) 
  87. REMOVE FLYWHEEL SUB-ASSEMBLY (See  REMOVAL   ) 
  88. INSTALL ENGINE STAND 
  89. REMOVE ENGINE HANGER NO.2 
    1. Remove the 2 bolts and engine hanger No.2.
      Fig 29: Identifying Engine Hanger
      G05238785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. REMOVE EMISSION CONTROL VALVE SET  (See REMOVAL )
  91. REMOVE INTAKE AIR SURGE TANK  (See REMOVAL )
  92. REMOVE INTAKE MANIFOLD (See  REMOVAL   ) 
  93. REMOVE WATER OUTLET (See  REMOVAL   ) 
  94. REMOVE IGNITION COIL ASSEMBLY 
  95. REMOVE MANIFOLD CONVERTER INSULATOR NO.3 (See  REMOVAL   ) 
  96. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See  REMOVAL   ) 
  97. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2 (See  REMOVAL   ) 
  98. REMOVE MANIFOLD STAY NO.2 
    1. Remove the 2 bolts and manifold stay No.2.
  99. REMOVE ENGINE MOUNTING BRACKET REAR 
    1. Remove the 3 bolts and engine mounting bracket rear.
      Fig 30: Locating Engine Mounting Bracket Rear, Bolts And Nuts
      G05200499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  100. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and engine mounting bracket RH.
      Fig 31: Locating Engine Mounting Bracket RH, Bolts And Nuts
      G05200500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  101. REMOVE ENGINE MOUNTING STAY BRACKET 
    1. Remove the bolt, nut and engine mounting stay bracket.
      Fig 32: Locating Engine Mounting Stay Bracket, Bolts And Nuts
      G05200501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  102. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 
    1. Remove the 4 bolts and compressor mounting bracket.
      Fig 33: Locating Compressor Mounting Bracket, Bolts And Nuts
      G05200502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  103. REMOVE INTAKE AIR CONNECTOR BRACKET NO.2 
    1. Remove the 2 bolts and intake air connector bracket No.2.
      Fig 34: Locating Intake Air Connector Bracket, Bolts And Nuts
      G05200503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  104. REMOVE WATER INLET PIPE  (See REMOVAL )
  105. REMOVE WATER INLET  (See INSTALLATION )
  106. REMOVE THERMOSTAT  (See INSTALLATION )
  107. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Using a deep socket wrench 24 mm, remove the oil pressure switch.
      Fig 35: Removing Oil Pressure Switch
      G05200504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  108. REMOVE KNOCK CONTROL SENSOR  (See INSPECTION )
  109. REPLACE PARTIAL ENGINE ASSEMBLY 
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