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Home >> Toyota >> 2018 >> Prius Two Eco >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - Service Information (1 Of 2) >> Engine Assembly & Engine Under Cover >> Removal [11/2015 - 08/2016] >> Procedure

Removal [11/2015 - 08/2016]: Procedure

  1. PRECAUTION 
    WARNING:

    The vehicle has a hybrid system that operates at voltages up to 650 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 - 11/2017]

    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.

    Refer to PRECAUTION [11/2015 - 11/2017]

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [11/2015 - 12/2018]

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

    Refer to PROCEDURE - Step 2

  5. REMOVE FRONT WHEELS 

    Refer to REMOVAL [11/2015 - 12/2018]

  6. REMOVE NO. 1 ENGINE UNDER COVER 
    1. Remove the 10 clips, 4 bolts and No. 1 engine under cover.
  7. REMOVE REAR MOTOR UNDER COVER LH 
    1. except Rough Road Area Specification Vehicles:
      1. Remove the 4 clips, screw and rear motor under cover LH.
    2. for Rough Road Area Specification Vehicles:
      1. Remove the 5 clips, screw and rear motor under cover LH.
  8. REMOVE REAR MOTOR UNDER COVER RH 
    1. except Rough Road Area Specification Vehicles:
      1. Remove the 4 clips, screw and rear motor under cover RH.
    2. for Rough Road Area Specification Vehicles:
      1. Remove the 5 clips, screw and rear motor under cover RH.
  9. REMOVE NO. 2 ENGINE UNDER COVER 
    1. Remove the 3 bolts and No. 2 engine under cover.
  10. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 2

  11. DRAIN ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  12. DRAIN HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 2

  13. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Disengage the 3 clips in the order shown in the illustration to remove the No. 1 engine cover sub-assembly.
      GTY728111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Areas to be Held when Lifting No. 1 Engine Cover Sub-assembly Remove in this Direction
      NOTE:
      • Pull the No. 1 engine cover sub-assembly straight up to remove. Attempting to pull the No. 1 engine cover sub-assembly forward or attempting to pull it up by holding the left and right sides may cause the No. 1 engine cover sub-assembly to break.
      • If the clips are not disengaged in the order shown in the illustration, the No. 1 engine cover sub-assembly may be damaged.
  14. DISCONNECT NO. 8 WATER BY-PASS HOSE 
    1. Slide the clip and disconnect the No. 8 water by-pass hose from the No. 2 water by-pass hose assembly.
      GTY550746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE RADIATOR SUPPORT OPENING COVER 

    Refer to PROCEDURE - Step 2

  16. REMOVE INLET NO. 2 AIR CLEANER 

    Refer to PROCEDURE - Step 3

  17. REMOVE THROTTLE BODY ASSEMBLY 

    Refer to REMOVAL [11/2015 - ]

  18. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  19. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  20. REMOVE AIR CLEANER BRACKET 

    Refer to PROCEDURE - Step 6

  21. REMOVE INLET NO. 1 AIR CLEANER 

    Refer to PROCEDURE - Step 7

  22. REMOVE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to REMOVAL [11/2015 - 12/2018]

  23. DISCONNECT NO. 3 RADIATOR HOSE 
    1. Remove the 2 bolts from the hybrid vehicle transaxle assembly.
      GTY567885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 3 radiator hose from the water outlet.
  24. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet sub-assembly.
      GTY604039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. DISCONNECT OUTLET HEATER WATER HOSE E 
    1. Slide the clip and disconnect the outlet heater water hose E from the No. 1 water by-pass pipe.
      GTY567905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT INLET HEATER WATER HOSE A 
    1. Slide the clip and disconnect the inlet heater water hose A from the EGR valve assembly.
      GTY567908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. GTY567910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Slide the clip and disconnect the No. 1 fuel vapor feed hose from the fuel vapor feed pipe.

  28. DISCONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  29. DISCONNECT INLET HYBRID RADIATOR HOSE 
    1. Slide the clip and disconnect the inlet hybrid radiator hose from the motor cooling cooler.
      GTY567883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. DISCONNECT OUTLET NO. 1 HYBRID WATER PUMP HOSE 
    1. Slide the clip and disconnect the outlet No. 1 hybrid water pump hose from the motor cooling cooler.
      GTY567906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. SEPARATE COMPRESSOR WITH MOTOR ASSEMBLY 
    1. Remove the bolt and disconnect the bracket.
      GTY568679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bracket
    2. Using a screwdriver, slide the green-colored lock of the connector (A) as shown in the illustration to release it and disconnect the connector.
      GTY589398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Connector (A)
      *b Connector (B)
      *c Green-colored Lock
      WARNING:

      Make sure to wear insulated gloves.

      NOTE:

      Insulate the disconnected terminals and connector with insulating tape.

    3. Disconnect the connector (B).
    4. Remove the 3 bolts and separate the compressor with motor assembly.
      GTY562671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. DISCONNECT NO. 3 ENGINE WIRE 
    1. Disengage the clamp.
      GTY567886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and disconnect the No. 3 engine wire from the hybrid vehicle transaxle assembly.
  33. REMOVE COLUMN HOLE COVER SILENCER SHEET 

    Refer to PROCEDURE - Step 14

  34. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 15

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

    Refer to PROCEDURE - Step 5

  36. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 6

  37. REMOVE FRONT FLOOR COVER RH 

    HINT: 

    Use the same procedure as for the LH side.

  38. REMOVE FRONT CENTER FLOOR BRACE 

    Refer to PROCEDURE - Step 8

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

    Refer to PROCEDURE - Step 9

  40. REMOVE FRONT AXLE SHAFT NUT LH 

    Refer to PROCEDURE - Step 6

  41. REMOVE FRONT AXLE SHAFT NUT RH 

    HINT: 

    Use the same procedure as for the LH side.

  42. SEPARATE FRONT SPEED SENSOR LH 

    Refer to PROCEDURE - Step 5

  43. SEPARATE FRONT SPEED SENSOR RH 

    HINT: 

    Use the same procedure as for the LH side.

  44. SEPARATE TIE ROD END SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 13

  45. SEPARATE TIE ROD END SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  46. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH 

    Refer to PROCEDURE - Step 9

  47. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

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

    Refer to PROCEDURE - Step 4

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

    HINT: 

    Use the same procedure as for the LH side.

  50. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 10

  51. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  52. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 12

  53. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  54. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING 

    Refer to PROCEDURE - Step 14

  55. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 11

  56. REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  57. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Place height adjustment attachments and plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine assembly with transaxle and front suspension crossmember sub-assembly.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle and front suspension crossmember sub-assembly 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.
      GTY563491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Attachment Installation Position
    2. Remove the nut.
      GTY567900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.
    4. Remove the 3 bolts and nut and separate the engine mounting insulator LH from the hybrid vehicle transaxle assembly.
      GTY567902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt and No. 2 engine mounting stay LH.
      GTY586182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 4 bolts and separate the front suspension crossmember sub-assembly from the vehicle body.
      GTY551816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Operate the engine lifter to remove the engine assembly with transaxle from the vehicle body.
      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 body.
  58. REMOVE WIRING HARNESS CLAMP BRACKET 
    1. Disengage the 3 clamps.
      GTY554939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and wiring harness clamp bracket from the cylinder head sub-assembly.
  59. INSTALL ENGINE HANGERS 
    1. Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts.
      GTY600591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      *3 Bolt

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

      HINT: 

      No. 1 Engine Hanger 12281-37021
      No. 2 Engine Hanger 12282-37011
      Bolt 91552-81050
    2. Using an engine sling device and engine lifter, secure the engine assembly with transaxle.
      NOTE:
      • Adjust the angle of the sling device carefully to prevent damage or deformation to the engine hangers or engine assembly.
      • 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.
  60. REMOVE ENGINE MOUNTING INSULATOR LH 

    HINT: 

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

    1. Remove the 4 bolts, nut and engine mounting insulator LH from the vehicle body.
      GTY567899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. 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 2 bolts and No. 2 earth wire from the engine mounting insulator sub-assembly RH and vehicle body.
      GTY606692Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. GTY567918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the bolt, nut and disconnect the 2 cooler brackets.

    3. Remove the 2 bolts, nut and engine mounting insulator sub-assembly RH from the vehicle body.
  62. REMOVE STARTER HOLE INSULATOR 

    Refer to PROCEDURE - Step 7

  63. REMOVE FLYWHEEL HOUSING SIDE COVER 

    Refer to PROCEDURE - Step 8

  64. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine assembly with transaxle.
  65. REMOVE ENGINE ASSEMBLY 

    Refer to PROCEDURE - Step 9

  66. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY 

    See step  2

  67. REMOVE FLYWHEEL SUB-ASSEMBLY 

    See step  3

  68. INSTALL ENGINE ASSEMBLY TO ENGINE STAND 
    1. Install the engine assembly to an engine stand.
      NOTE:
      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.
      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.
  69. REMOVE ENGINE HANGERS 
    1. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.
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