Removal

2AZ-FXE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

REMOVAL

1. PRECAUTION
HINT: Hybrid Control System.

2. REMOVE LUGGAGE TRIM SERVICE HOLE COVER
3. DISCHARGE FUEL SYSTEM PRESSURE
HINT: Technician Safety Information.

4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL Removal
5. REMOVE SERVICE PLUG GRIP Removal
6. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
7. REMOVE FRONT WHEELS
8. REMOVE ENGINE UNDER COVER LH
9. REMOVE ENGINE UNDER COVER RH
10. REMOVE FRONT FENDER APRON SEAL RH
11. DRAIN ENGINE OIL Replacement
12. DRAIN COOLANT (for Engine) Testing and Inspection
13. DRAIN COOLANT (for Inverter) Service and Repair
14. DRAIN HYBRID TRANSAXLE FLUID Procedures
15. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal
16. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal
17. REMOVE FRONT FENDER TO COWL SIDE SEAL LH Removal
18. REMOVE FRONT FENDER TO COWL SIDE SEAL RH Removal
19. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal
20. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Removal
21. SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
22. REMOVE COWL TOP PANEL OUTER SUB-ASSEMBLY Removal
23. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Remove the 2 nuts and cover.
24. REMOVE V-RIBBED BELT TENSIONER COVER SUB-ASSEMBLY Removal
25. REMOVE V-RIBBED BELT Removal
26. REMOVE AIR CLEANER INLET ASSEMBLY

(a) Remove the 2 bolts, clamp and air cleaner inlet.
27. REMOVE AIR CLEANER CAP SUB-ASSEMBLY Removal
28. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

(a) Disconnect the hose clamp.
(b) Remove the 3 bolts and air cleaner case.
29. REMOVE INVERTER WITH CONVERTER ASSEMBLY
HINT: Removal.

30. SEPARATE WATER WITH MOTOR AND BRACKET PUMP ASSEMBLY Removal
31. REMOVE INVERTER TRAY BRACKET

(a) Remove the 4 bolts and inverter tray bracket.
32. REMOVE NO. 2 ENGINE MOUNTING STAY RH

(a) Remove the 2 bolts and No. 2 engine mounting stay RH.
33. REMOVE ENGINE MOVING CONTROL ROD SUB-ASSEMBLY

(a) Remove the 3 bolts and the engine moving control rod with bracket.
34. REMOVE NO. 2 ENGINE MOUNTING BRACKET RH

(a) Remove the bolt and disconnect the ground cable.
(b) Remove the 3 bolts and No. 2 engine mounting bracket RH.
35. DISCONNECT RADIATOR HOSE INLET

(a) Remove the clamp and disconnect the radiator hose inlet.
36. DISCONNECT RADIATOR HOSE OUTLET

(a) Remove the clamp and disconnect the radiator hose outlet.
37. DISCONNECT WATER HOSE

(a) Remove the 2 clamps and disconnect the 2 water hoses.
38. DISCONNECT HEATER INLET WATER HOSE

(a) Disconnect the heater inlet water hose.
39. DISCONNECT HEATER OUTLET WATER HOSE
(a) Disconnect the heater outlet water hose.
40. REMOVE HYBRID VEHICLE CONTROL ECU Removal
41. REMOVE POWER STEERING ECU ASSEMBLY Removal
42. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the engine room relay block.

(1) Remove the nut and separate the wire harness.
(2) Using a screwdriver, unlock the engine room R/B. Pull the engine room R/B upward.

(3) Disconnect the clamps and engine wire connectors.

(b) Remove the 2 bolts and clamp from the body.

(d) Release the lock lever of the connector as shown in the illustration.
(e) Disconnect the 3 connectors from the power steering link assembly.
(f) Remove the 2 bolts and power steering wire from the power steering link assembly.
43. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Remove the clip and nut, and separate the control lever.
(b) Disconnect the cable from the clamp.
44. DISCONNECT FUEL TUBE SUB-ASSEMBLY

(a) Remove the No. 1 fuel pipe clamp.

(b) Disconnect the connector from the tube while pinching part A with your fingers as shown in the illustration.
NOTICE :
- Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector.
- Disconnect the connector by hand.
- Do not bend, fold or rotate the nylon tube.
- If the pipe and connector are stuck together, push and pull the connector until it becomes free.
- Put the pipe and connector ends in vinyl bags to prevent damage and contamination.

45. SEPARATE ELECTRIC INVERTER COMPRESSOR

(a) Release the green-colored lock.
CAUTION: Wear insulated gloves when performing the procedures.

(b) Disconnect the 2 connectors.
NOTICE: Insulate the connector by sealing it with tape.

(d) Remove the 3 bolts and separate the compressor.
HINT: Hang up the hoses instead of detaching them.

46. REMOVE FRONT EXHAUST PIPE ASSEMBLY
HINT: Removal.

47. REMOVE FRONT AXLE HUB NUT LH Removal
48. REMOVE FRONT AXLE HUB NUT RH
HINT: Use the same procedures described for the LH side.

49. REMOVE FRONT STABILIZER LINK ASSEMBLY LH Removal
50. REMOVE FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

51. REMOVE FRONT SPEED SENSOR LH Removal
52. REMOVE FRONT SPEED SENSOR RH
HINT: Use the same procedures described for the LH side.

53. DISCONNECT TIE ROD ASSEMBLY LH Removal
54. DISCONNECT TIE ROD ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

55. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM LH Removal
56. DISCONNECT FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT: Use the same procedures described for the LH side.

57. SEPARATE FRONT AXLE ASSEMBLY LH Removal
58. SEPARATE FRONT AXLE ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

59. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET
(a) Remove the 2 bolts and No. 1 exhaust pipe support bracket.
60. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY Removal
61. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.
(b) Remove the 4 bolts, 2 nuts and frame side rail plate RH and LH.

(c) Remove the 4 bolts, 2 nuts and front suspension member brace rear RH and LH.
(d) Carefully remove the engine assembly from the vehicle.

(e) Install the 2 engine hangers as shown in the illustration.
Parts No.:

Torque: 38 Nm (387 kgf-cm, 28ft-lbf)
(f) Using a chain block and an engine sling device, hang the engine assembly.
62. REMOVE HV TRANSAXLE MASS DAMPER

(a) Remove the bolt and transaxle mass damper.
63. REMOVE FRONT FRAME ASSEMBLY

(a) Remove the 2 nuts and separate the engine mounting insulators RH and LH.

(b) Remove the bolt from the engine mounting insulator FR.
(c) Raise the engine assembly and separate the front frame.
64. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal
65. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal
66. REMOVE ENGINE WIRE
67. SEPARATE HYBRID VEHICLE TRANSAXLE ASSEMBLY
HINT: Removal.

68. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY Removal
69. REMOVE FLYWHEEL SUB-ASSEMBLY Removal
70. INSTALL ENGINE STAND
(a) Fix the engine onto an engine stand with the bolts.
71. REMOVE FUEL DELIVERY PIPE WITH INJECTOR Removal
72. REMOVE INTAKE MANIFOLD

(a) Remove the 5 bolts, 2 nuts, and intake manifold.

(b) Remove the gasket from the intake manifold.
73. REMOVE NO. 2 VENTILATION HOSE
74. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR

(a) Remove the No. 1 intake manifold insulator from the cylinder block.
75. REMOVE DRIVE SHAFT BEARING BRACKET

(a) Remove the 3 bolts and drive shaft bearing bracket.
76. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY
77. REMOVE OIL LEVEL GAUGE GUIDE

(a) Remove the bolt and oil level gauge guide.
(b) Remove the O-ring from the oil level gauge guide.
78. REMOVE MANIFOLD STAY

(a) Remove the bolt, nut and stay.
79. REMOVE NO. 2 MANIFOLD STAY

(a) Remove the bolt, nut and stay.
80. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

(a) Disconnect the air-fuel ratio sensor connector.

(b) Remove the 5 nuts, manifold converter and gasket.
81. REMOVE WATER INLET Removal
82. REMOVE THERMOSTAT Removal
83. REMOVE NO. 1 WATER BY-PASS PIPE

(a) Remove the bolt, 2 nuts and No. 1 water by-pass pipe with the gasket.
84. REMOVE IDLER PULLEY BRACKET

(a) Loosen the 2 bolts and remove the idler pulley bracket from the engine.
85. REMOVE ENGINE MOUNTING BRACKET RH

(a) Remove the 3 bolts and engine mounting bracket RH.
86. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

(a) Remove the 2 bolts and belt tensioner.
87. REMOVE IGNITION COIL ASSEMBLY
(a) Remove the 4 bolts and 4 ignition coils.
88. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Removal
89. REMOVE KNOCK SENSOR
(a) Disconnect the sensor connector.
(b) Remove the nut and sensor.
90. REMOVE RADIO SETTING CONDENSER

(a) Remove the bolt and radio setting condenser.
91. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
92. REMOVE ENGINE COOLANT TEMPERATURE SENSOR

(a) Using SST, remove the sensor and gasket.
SST: 09817-33190