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Home >> Toyota >> 2025 >> Prius Plug-In Hybrid SE >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical System - Service Information (2 Of 4) >> ENGINE ASSEMBLY (for HEV Model) >> Removal [12/2022 - ] >> Procedure

Removal [12/2022 - ]: Procedure

  1. PRECAUTION 
    NOTE:
    • After the ignition switch is turned off, there may be a waiting time before disconnecting the negative (-) auxiliary battery terminal.

      Refer to BEFORE DISCONNECTING BATTERY [12/2022 - ]

    • When replacing the auxiliary battery, use a new auxiliary battery of the same dimensions and same capacity or more from the same class at a 20-hour rate.
    • After replacing the auxiliary battery, install the ventilation hole plug supplied with the new auxiliary battery or the ventilation hole plug from the old auxiliary battery to the ventilation hole on the side to which the battery hose is not connected.
  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 
  3. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [12/2022 - 03/2023] , or refer to PRECAUTION [03/2023 - ]

  4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 

    Refer to PROCEDURE - Step 2 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 2 [03/2023 - ]

  5. SECURE STEERING WHEEL 
    Refer to PROCEDURE - Step 2
  6. REMOVE FRONT WHEELS 

    Refer to REMOVAL [12/2022 - ]

  7. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 
    1. GTY1160072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 
    1. GTY1160071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE CENTER ENGINE UNDER COVER 
    1. GTY1159656Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Screw
  10. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY 
    1. GTY1152138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE REAR ENGINE UNDER COVER LH 
    1. GTY1150172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE REAR ENGINE UNDER COVER RH 
    1. GTY1150174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE FRONT FLOOR COVER LH 
    Refer to PROCEDURE - Step 6 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 6 [03/2023 - ]
  14. REMOVE FRONT FLOOR COVER RH 
    Refer to PROCEDURE - Step 7 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 7 [03/2023 - ]
  15. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 2 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 2 [03/2023 - ]

  16. DRAIN ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 1

  17. DRAIN HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 2 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 2 [03/2023 - ]

  18. REMOVE FRONT BUMPER ASSEMBLY 

    Refer to REMOVAL [12/2022 - ]

  19. REMOVE FRONT BUMPER LOWER ABSORBER 

    Refer to PROCEDURE - Step 37 [12/2022 - 01/2025] , or refer to PROCEDURE - Step 35 [01/2025 - ]

  20. REMOVE NO. 2 FRONT BUMPER REINFORCEMENT 

    Refer to PROCEDURE - Step 43 [12/2022 - 01/2025] , or refer to PROCEDURE - Step 41 [01/2025 - ]

  21. REMOVE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to REMOVAL [12/2022 - ]

  22. DISCONNECT NO. 7 ENGINE WIRE 
    1. GTY1152131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT INVERTER RESERVE TANK ASSEMBLY 
    1. GTY1152132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 7 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 7 [03/2023 - ]
  25. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 8 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 8 [03/2023 - ]
  26. DISCONNECT NO. 1 RADIATOR HOSE 
    1. GTY1149527Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT NO. 2 RADIATOR HOSE 
    1. GTY1152153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT INLET NO. 1 INVERTER COOLING HOSE 
    1. GTY1152154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. DISCONNECT OUTLET NO. 2 INVERTER COOLING HOSE 
    Refer to PROCEDURE - Step 9 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 9 [03/2023 - ]
  30. REMOVE NO. 1 FUEL VAPOR FEED HOSE 
    1. GTY1152142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. DISCONNECT WATER HOSE SUB-ASSEMBLY 
    1. GTY1150689Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer - -
      Pull out Pull off
      1. Disconnect the water hose sub-assembly connector.
        NOTE:

        Remove any foreign matter on the water hose sub-assembly connector before performing this work.

        1. Pull out the retainer to disengage the lock claws and pull off the water hose sub-assembly connector.

        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 water hose and water hose sub-assembly connector with a plastic bag to prevent damage and contamination.

    2. GTY1146615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer - -
      Pull out Pull off
      1. Disconnect the water hose sub-assembly connector.
        NOTE:

        Remove any foreign matter on the water hose sub-assembly connector before performing this work.

        1. Pull out the retainer to disengage the lock claws and pull off the water hose sub-assembly connector.

        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 water hose and water hose sub-assembly connector with plastic bags to prevent damage and contamination.

  32. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. GTY1156895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disengage the claw and remove the EFI fuel pipe clamp as shown in the illustration.
      2. Disconnect the fuel tube sub-assembly from the fuel pipe.

        Refer to PRECAUTION [12/2022 - 03/2023] , or refer to PRECAUTION [03/2023 - ]

  33. DISCONNECT NO. 4 WATER BY-PASS HOSE 
    1. GTY1152152Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE COLUMN HOLE COVER SILENCER SHEET 

    Refer to PROCEDURE - Step 16 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 16 [03/2023 - ]

  35. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 
    Refer to PROCEDURE - Step 17 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 17 [03/2023 - ]
  36. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY 
    1. GTY1154811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Separate the 2 clips (A), disengage the clip (B) from the vehicle body and separate the No. 1 steering column hole cover sub-assembly.
        NOTE:

        Do not damage the clips (A) or (B).

  37. REMOVE FRONT FLOOR CENTER BRACE 

    Refer to PROCEDURE - Step 8 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 8 [03/2023 - ]

  38. REMOVE FRONT EXHAUST PIPE ASSEMBLY 
    Refer to PROCEDURE - Step 9 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 10 [03/2023 - ]
  39. REMOVE DRIVE SHAFT ASSEMBLY 

    Refer to REMOVAL [12/2022 - ]

  40. REMOVE NO. 2 CROSSMEMBER GUSSET LH 
    1. GTY1145177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE NO. 2 CROSSMEMBER GUSSET RH 
    1. GTY1145176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE FRONT BUMPER EXTENSION SUB-ASSEMBLY LH 
    1. GTY1152158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE FRONT BUMPER EXTENSION SUB-ASSEMBLY RH 
    1. GTY1141759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. GTY1151733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Attachment Installation Position - -
      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 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.
        • To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.
        • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.
    2. GTY1148309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Center Radiator Support LH *2 Center Radiator Support RH
      Bolt Nut
      1. Remove the 2 bolts and nut and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.
      2. Remove the 3 bolts and nut and separate the engine mounting insulator LH from the hybrid vehicle transaxle assembly.
      3. Remove the 2 bolts and No. 2 engine mounting stay LH.
      4. Remove the 8 bolts to separate the front suspension crossmember sub-assembly, center radiator support LH and center radiator support RH from the vehicle.
      5. 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.
  45. REMOVE ENGINE MOUNTING BRACKET CAP 
    1. GTY1148378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Turn over the engine mounting bracket cap to the upper part.
      2. While rotating in the direction shown in the illustration, remove the engine mounting bracket cap.
  46. INSTALL ENGINE HANGERS 
    1. GTY1153317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger
      1. Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.

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

        HINT: 

        No. 1 Engine Hanger 12281-25030
        No. 2 Engine Hanger 12282-25010
        Bolt 91552-F1040
      2. Attach an engine sling device and hang the engine assembly with transaxle with a chain block.
        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 procedure while the engine assembly with transaxle is suspended because doing so may cause the engine assembly with transaxle to drop, resulting in injury. However, the engine assembly with transaxle needs to be suspended when it is installed to or removed from an engine stand.
  47. DISCONNECT ENGINE WIRE 
    Refer to PROCEDURE - Step 5 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 5 [03/2023 - ]
  48. REMOVE STARTER HOLE INSULATOR 

    Refer to PROCEDURE - Step 6 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 6 [03/2023 - ]

  49. REMOVE FLYWHEEL HOUSING SIDE COVER 

    Refer to PROCEDURE - Step 7 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 7 [03/2023 - ]

  50. REMOVE ENGINE ASSEMBLY 
    Refer to PROCEDURE - Step 8 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 8 [03/2023 - ]
  51. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY 
    See step  2 [12/2022 - 03/2023], or see step  2 [03/2023 - ]
  52. REMOVE FLYWHEEL SUB-ASSEMBLY 
    See step  3 [12/2022 - 03/2023], or see step  3 [03/2023 - ]
  53. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 

    See step  4 [12/2022 - 03/2023], or see step  4 [03/2023 - ]

  54. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY 
    Refer to PROCEDURE - Step 9 [12/2022 - 03/2023] , or refer to PROCEDURE - Step 9 [03/2023 - ]
  55. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. GTY1149524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE ENGINE WIRE 

    HINT: 

    As the illustration shown is an example, the actual details may differ.

    GTY1150165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. INSTALL ENGINE ASSEMBLY TO ENGINE STAND 
    1. GTY996339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE ENGINE HANGERS 
  59. REMOVE ENGINE MOUNTING INSULATOR LH 

    HINT: 

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

    1. GTY1152110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. 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. GTY1140300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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