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Home >> Toyota >> 2016 >> Prius C One >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (Service Information) >> Engine Assembly >> Removal [11/2015 - 06/2017] >> Procedure

Removal [11/2015 - 06/2017]: Procedure

  1. PRECAUTION 
    WARNING:

    The vehicle has a hybrid system that operates at voltages up to 520 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this information to handle the system correctly. Failure to do so may result in serious injury or electrocution (Refer to PRECAUTION [11/2015 - 06/2017] ).

    NOTE:

    After turning the ignition 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 (Refer to PRECAUTION [11/2015 - 06/2017] ).

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  3. DISCHARGE FUEL SYSTEM PRESSURE 

    (Refer to PRECAUTION [11/2015 - ] )

  4. REMOVE SERVICE PLUG GRIP 

    (Refer to REMOVAL [11/2015 - ] )

  5. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL 

    (Refer to REMOVAL [11/2015 - 06/2017] )

  6. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY 
    1. Remove the 6 screws, 5 bolts, 2 clips and No. 1 engine under cover assembly.
  7. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 1

  8. DRAIN COOLANT (for Engine) 

    Refer to PROCEDURE - Step 1

  9. DRAIN COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 1

  10. DRAIN HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 1

  11. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    (Refer to REMOVAL [11/2015 - ] )

  12. REMOVE INNER COWL TOP TO COWL BRACE 

    Refer to PROCEDURE - Step 4

  13. REMOVE FRONT AIR SHUTTER SEAL 

    Refer to PROCEDURE - Step 5

  14. REMOVE FRONT NO. 1 VENTILATOR SEAL 

    Refer to PROCEDURE - Step 6

  15. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  16. REMOVE INVERTER WITH CONVERTER ASSEMBLY 

    (Refer to REMOVAL [11/2015 - ] )

  17. REMOVE AIR CLEANER CAP SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  18. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  19. REMOVE INVERTER BRACKET ASSEMBLY 
    WARNING:

    Wear insulated gloves.

    1. Remove the bolt and separate the motor cable protector.
      GTY717558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 wire harness clamps.
      GTY717559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and separate the inverter reservoir tank assembly.
      GTY337445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and disconnect the earth wire.
      GTY337446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 4 bolts and inverter bracket assembly.
      GTY325297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 1 radiator hose from the engine assembly.
      GTY339750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 2 radiator hose from the engine assembly.
      GTY324752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT HEATER WATER HOSE 
    1. Slide the 2 clips and disconnect the 2 heater water hoses from the engine assembly.
      GTY339748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY 
    1. Slide the clip and disconnect the fuel vapor feed hose assembly.
      GTY339749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 10

  25. DISCONNECT ENGINE WIRE 
    1. Push the lock on the lever, then raise the lever, and disconnect the ECM connector.
      GTY337444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      If there is any foreign matter such as mud or water on a connector, clean the connector.

    2. Disconnect the 2 wire harness clamps.
    3. Disconnect the 2 connectors and wire harness clamp.
      GTY717560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a screwdriver, disengage the claw and disconnect the engine wire from the engine room relay block and junction block assembly.
    5. Disconnect the engine wire from the engine room main wire.
      GTY337443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Disconnect the wire harness clamp.
  26. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 16

  27. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  28. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 2

  29. REMOVE COLUMN HOLE COVER SILENCER SHEET 

    Refer to PROCEDURE - Step 9

  30. SEPARATE STEERING SLIDING YOKE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 10

  31. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  32. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 5

  33. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  34. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 7

  35. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 2

  36. SEPARATE NO. 2 ENGINE ROOM RELAY BLOCK AND NO. 2 JUNCTION BLOCK ASSEMBLY 

    See step  3

  37. REMOVE FRONT DRIVE SHAFT ASSEMBLY 

    (Refer to REMOVAL [11/2015 - ] )

  38. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the flywheel housing under cover.
      GTY337387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
      GTY328578Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 2 Oil Pan Sub-assembly
      *2 Drain Plug
      *3 Rear Cover Plug
      Attachment Installation Position
      NOTE:
      • Place the height adjustment attachment and plate lift attachment so that the engine assembly with transaxle is level.
      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.
      • Do not place any attachments onto the drain plug and rear cover plug of the hybrid vehicle transaxle assembly.
    2. Remove the bolt and 2 nuts, and separate the engine mounting insulator sub-assembly RH from the engine assembly.
      GTY329343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and nut, and separate the engine mounting insulator LH from the engine mounting bracket LH.
      GTY337384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 6 bolts, operate the engine lifter and slowly remove the engine assembly with transaxle and front suspension crossmember sub-assembly from the vehicle.
      GTY325283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that the engine is clear of all wiring and hoses.

  40. INSTALL NO. 1 ENGINE HANGER 
    1. Install the 2 No. 1 engine hangers with 2 new bolts.
      GTY336877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 44 N*m (448 kgf*cm, 32 ft.*lbf) 

      Part Name Part No.
      No. 1 Engine Hanger 12281-21090
      Bolt 91672-81025
  41. FIX ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Attach the sling device to the engine hangers and chain block.
      NOTE:

      Make sure that the sling angle is correct to prevent the engine assembly and engine hangers from being damaged or deformed.

    2. To enable removal of the engine assembly, adjust the positions of the height adjustment attachment and plate lift attachment and set them in place.
      GTY331443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 2 Oil Pan Sub-assembly
      *2 Drain Plug
      *3 Rear Cover Plug
      Attachment Installation Position
      NOTE:
      • Place the height adjustment attachment and plate lift attachment so that the engine assembly with transaxle is level.
      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.
      • Do not place any attachments onto the drain plug and rear cover plug of the hybrid vehicle transaxle assembly.
    3. Using a rope or belt, secure the engine assembly with transaxle to the engine lifter.
      GTY340993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Set the engine assembly with transaxle so that it is horizontal.
      • Do not tighten the rope or belt with a tightening mechanism or any more than is necessary.
  42. REMOVE ENGINE ASSEMBLY 
    1. Disconnect the 4 clamps and No. 2 engine wire.
      GTY724488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and disconnect the 4 connectors, 7 clamps and wire harness from the hybrid vehicle transaxle assembly.
      GTY728102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 bolts, 2 wire harness clamp brackets and transmission control cable clamp from the hybrid vehicle transaxle assembly.
      GTY690104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Wire Harness Clamp Bracket
      *2 Transmission Control Cable Clamp
    4. Remove the bolt, nut and drive shaft heat insulator sub-assembly from the engine assembly and drive shaft heat insulator bracket.
      GTY724429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the clamp from the drive shaft heat insulator bracket.
      GTY724428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 bolts and drive shaft heat insulator bracket from the engine assembly.
    7. Remove the 2 bolts and starter hole heat insulator from the engine assembly.
      GTY739261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Disengage the claw and remove the flywheel housing side cover from the engine assembly.
      GTY703691Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the 6 bolts and hybrid vehicle transaxle assembly.
      GTY702593Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • To avoid damage to the knock pins, do not pry between the hybrid vehicle transaxle assembly and the engine assembly.
      • To prevent the splines of the damper from becoming misaligned, do not allow the transaxle to hit the damper during transaxle removal and installation.
  43. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY 
    1. Gently place the engine assembly onto wood blocks or equivalent.
      NOTE:
      • Set the engine assembly so that it is horizontal.
      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.
      • This step should be done while hanging the engine assembly using the sling device and chain block.
    2. Remove the transmission input damper assembly See step  2).
  44. REMOVE FLYWHEEL SUB-ASSEMBLY 
    1. Gently place the engine assembly onto wooden blocks or equivalent.
      NOTE:
      • Set the engine assembly so that it is horizontal.
      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.
      • This step should be done while hanging the engine assembly using the sling device and chain block.
    2. Remove the flywheel sub-assembly See step  3).
  45. 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. Remove the 3 bolts and engine mounting insulator sub-assembly RH.
      GTY329349Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE ENGINE MOUNTING INSULATOR LH 

    HINT: 

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

    1. Disconnect the wire harness clamp.
      GTY337385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and engine mounting insulator LH.
  47. INSTALL ENGINE STAND 
    1. Using a sling device and chain block, install the engine stand to the engine assembly.
      NOTE:
      • Make sure that the sling angle is correct to prevent the engine assembly and engine hangers from being damaged or deformed.
      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
  48. DISCONNECT ENGINE WIRE 
    1. Disconnect all of the clamps and connectors and remove the engine wire from the engine assembly.
  49. REMOVE NO. 1 ENGINE HANGER 
    1. Remove the 2 bolts and 2 No. 1 engine hangers.
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