Diesel Data: Automotive Repair
Home >> Toyota >> 2009 >> Prius L4-1.5L (1NZ-FXE) Hybrid >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Removal

Removal








1NZ-FXE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

REMOVAL

1. PRECAUTION
CAUTION: The hybrid system uses high voltage circuits, so improper handling could cause an electric shock or leakage. During service (e.g. installing or removing the parts, inspection, replacing the parts), be sure to follow the procedures Service Precautions.

2. REMOVE NO. 2 REAR FLOOR BOARD Removal
3. REMOVE REAR DECK FLOOR BOX Removal
4. REMOVE NO. 3 REAR FLOOR BOARD Removal
5. DISCHARGE FUEL SYSTEM PRESSURE Removal
6. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable to prevent airbag and seat belt pretensioner activation.

7. REMOVE SERVICE PLUG GRIP Removal
8. REMOVE FRONT WHEELS
9. REMOVE NO. 3 ENGINE UNDER COVER
10. REMOVE NO. 4 CENTER ENGINE UNDER COVER Removal
11. DRAIN ENGINE COOLANT Testing and Inspection
12. DRAIN TRANSAXLE OIL Removal
13. REMOVE WIPER ARM HEAD CAP
14. REMOVE FRONT WIPER ARM LH Removal
15. REMOVE FRONT WIPER ARM RH Removal
16. REMOVE HOOD TO COWL TOP SEAL Removal
17. REMOVE COWL TOP VENTILATOR LOUVER LH Removal
18. REMOVE COWL TOP VENTILATOR LOUVER RH Removal
19. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Removal
20. REMOVE FRONT OUTER COWL TOP PANEL Removal
21. REMOVE INVERTER WITH CONVERTER ASSEMBLY
(a) Remove the inverter with converter from the vehicle Removal.
22. REMOVE NO. 2 RADIATOR ASSEMBLY
(a) Remove the No. 2 radiator from the vehicle Removal.





23. DISCONNECT NO. 3 INVERTER COOLING HOSE
24. DISCONNECT NO. 1 HEAT STORAGE WATER BY-PASS HOSE





(a) Disconnect the hose shown in the illustration.
25. DISCONNECT ENGINE WIRE





(a) Remove the bolt, then disconnect the ground cable.
26. SEPARATE NO. 1 AIR CLEANER INLET





(a) Loosen the clamp, then disconnect the air cleaner inlet No. 1 from the air cleaner case.
27. REMOVE PURGE VSV





(a) Disconnect the connector and hose.
(b) Remove the bolt, then remove the vacuum switching valve assembly.
28. DISCONNECT FUEL TUBE





(a) Remove the fuel pipe clamp.





(b) Disconnect the fuel tube from the fuel delivery pipe.
NOTE: Even if the fuel tube is stuck and cannot be disconnected, do not use any tools. Push and pull the part with the quick connector pinched to disconnect the tube.

(c) Cover the disconnected fuel tube and fuel delivery pipe with plastic bags in order to prevent foreign objects from entering them.





29. DISCONNECT HEATER WATER HOSE





30. DISCONNECT NO. 3 HEAT STORAGE WATER BY-PASS HOSE
31. DISCONNECT ENGINE WIRE





(a) Disconnect the connector from the ECM, then pull the engine wire harness to the engine compartment side.
NOTE: Do not forcibly pull the engine wire harness to the engine compartment side.

(b) Disconnect the harness and harness clamp from the engine room main relay block.
(c) Disconnect the ground cable.
32. DISCONNECT HEATER COMPRESSOR WITH MOTOR ASSEMBLY





(a) Disconnect the wire harness of the compressor assembly from the harness clamp.
(b) Remove the 3 bolts, then disconnect the compressor assembly.
HINT: Disconnect the compressor assembly together with the low-pressure and high-pressure hoses, then secure it to the vehicle side with rope.

33. DISCONNECT STEERING SLIDING YOKE





(a) Install the seat belt as illustrated so that the steering wheel does not turn.
HINT: This prevents an open circuit of the spiral cable.





(b) Remove the 2 clips, then remove the column hole cover silencer sheet.





(c) Loosen the bolt on the column side (A) of the sliding yoke.
(d) Remove the bolt on the gear side (B) of the sliding yoke.
(e) Put paint marks on the sliding yoke and intermediate shaft, and then disconnect the sliding yoke.
34. REMOVE FRONT EXHAUST PIPE Removal
35. REMOVE FRONT AXLE HUB NUT LH Removal
36. REMOVE FRONT AXLE HUB NUT RH
HINT: Use the same procedures described for the LH side.

37. DISCONNECT FRONT STABILIZER LINK LH Removal
38. DISCONNECT TIE ROD END LH Removal
39. DISCONNECT TIE ROD END RH
HINT: Use the same procedures described for the LH side.

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

42. DISCONNECT FRONT AXLE HUB LH Removal
43. DISCONNECT FRONT AXLE HUB RH
HINT: Use the same procedures described for the LH side.

44. REMOVE FRONT DRIVE SHAFT LH Removal
45. REMOVE FRONT DRIVE SHAFT RH Removal
46. REMOVE FRONT SUSPENSION CROSSMEMBER





(a) Remove the 4 bolts and 2 nuts, then remove the engine moving control rod with bracket.





(b) Remove the 4 bolts, then remove the front suspension crossmember with power steering gear assembly.
47. REMOVE ENGINE AND TRANSAXLE





(a) Set the engine lifter as illustrated.





(b) Remove the 2 bolts and 2 nuts, then disconnect the engine mounting bracket RH and engine mounting insulator RH.
(c) Remove the nut, then disconnect the engine mounting insulator bracket LH and engine mounting insulator LH.
(d) Operate the engine lifter, then remove the engine assembly with transaxle from the vehicle.
48. REMOVE AIR CLEANER ASSEMBLY





(a) Disconnect the intake air flow meter connector and wire harness clamp.
(b) Loosen the clamp, then remove the 2 bolts and air cleaner assembly.
49. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY





(a) Remove the bolt and ground cable.





(b) Install the engine hangers to the engine assembly with 2 new bolts as shown in the illustration.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
NOTE: Be sure to use new bolts to install the engine hangers.

HINT:
- Engine hanger 12281-21010
- Bolt 91642-81052

(c) Using a chain block and engine sling device, hold the engine assembly with transaxle.
(d) Remove the engine wire harness from the engine assembly with transaxle.





(e) Remove the 2 bolts, then remove the starter hole insulator and flywheel housing side cover.
(f) Remove the hybrid vehicle transaxle assembly from the engine assembly Removal.
50. REMOVE TRANSMISSION INPUT DAMPER





(a) Using SST, hold the crankshaft.
SST: 09213-58013
91111-50845
SST: 09330-00021
(b) Remove the 6 bolts, then remove the input damper and input damper cover.
51. REMOVE FLYWHEEL





(a) Using SST, hold the crankshaft.
SST: 09213-58013
91111-50845
SST: 09330-00021
(b) Remove the 6 bolts and flywheel.
52. REMOVE OIL DIPSTICK GUIDE





(a) Remove the dipstick.
(b) Remove the bolt and dipstick guide.
53. REMOVE INTAKE MANIFOLD





(a) Remove the bolt and knock control sensor with bracket.
(b) Disconnect the wiring harness from the bracket.
(c) Disconnect the ventilation hose.
(d) Disconnect the water by-pass hose.





(e) Remove the 3 bolts and 2 nuts, then remove the intake manifold and gasket.
54. REMOVE NO. 1 WATER BY-PASS PIPE





(a) Remove the bolt, then disconnect the wire harness.
(b) Remove the 2 nuts and bolt, then remove the water by-pass pipe No. 1 and gasket.
55. REMOVE KNOCK SENSOR Removal
56. REMOVE ENGINE OIL PRESSURE SWITCH Testing and Inspection
57. REMOVE DRIVE BELT Removal
58. REMOVE IDLER PULLEY





(a) Remove the nut, then remove the idle pulley assembly from the engine mounting bracket RH.
59. REMOVE IGNITION COIL





(a) Remove the 4 bolts and 4 ignition coils.
60. REMOVE EXHAUST MANIFOLD





(a) Remove the 4 bolts and exhaust manifold insulator.





(b) Remove the 3 bolts and 2 nuts, then remove the exhaust manifold.
61. REMOVE NOISE FILTER





(a) Remove the bolt and noise filter.
62. REMOVE ENGINE COOLANT TEMPERATURE SENSOR





(a) Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor.
Diesel-Data.com