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Removal and Installation
 
 
dangerPHEV vehicles have high voltage batteries, so incorrect handling may cause electric shock and electric leakage. Work correctly, according to the work procedure, when performing inspection and maintenance.
warning
  • Before inspecting or servicing high-voltage wiring harnesses and components, be sure to disconnect the service plug to cut off the high-voltage circuit.
  • Keep the removed service plug in your pocket, or place it in a toolbox or other receptacle, while you are working, to make sure nobody else can mistakenly connect it while you are working.
  • Always wear insulative protector while working on high-voltage systems.
  • When working with high-voltages, clearly decide who is in charge, and make sure nobody else touches the vehicle. Also, whenever you are not working on them, cover the high-voltage parts with an electricity-resistant cover sheet etc. so that nobody else can touch them.
  • Refer to PRECAUTIONS ON HOW TO USE THE HIGH-VOLTAGE VEHICLE.
caution
  • When the vehicle is in the READY state, with the service plug detached, faults can occur in the vehicle. Therefore, do not put the vehicle in READY state other than when instructed by the workshop manual to do so.
  • Work with safety in mind, and do not attempt anything risky.
  • Do not start work before the exhaust system and engine coolant have cooled down.
  • Use the specified support points when lifting. Refer to LIFTING, JACKING SUPPORT LOCATION.
  • If the front transaxle assembly is removed or installed, perform the following tasks in numerical order.
    1. Stored Range Value Clear (Refer to STORED RANGE VALUE CLEAR.)
    2. Leaning of Movable Range (Refer to LEARNING OF MOVABLE RANGE.)
    3. Check Initial Learning Quantity (Refer to CHECK INITIAL LEARNING QUANTITY.)
 
 
REMOVAL
 
 
Outline
Without disconnecting the A/C piping, lower the assembly (which consists of the engine, the generator, the front motor and the front transaxle assembly) slightly to the lower side of the vehicle, and remove the engine mounting insulators (LH and RH) from the gap.
 
 
Preparation
1. Release the fuel pressure in the fuel line. Refer to FUEL PUMP CONNECTOR DISCONNECTION (HOW TO REDUCE PRESSURIZED FUEL PRESSURE).
2. Shut off the high-voltage circuit. Refer to PRECAUTIONS ON HOW TO USE THE HIGH-VOLTAGE VEHICLE.
3. Check the voltage of the high-voltage circuit. Refer to PRECAUTIONS ON HOW TO USE THE HIGH-VOLTAGE VEHICLE.
4. Drain the engine coolant. Refer to ENGINE COOLANT REPLACEMENT.
5. Drain the EV coolant. Refer to EV COOLANT CHANGE.
6. Drain the engine oil. Refer to ENGINE OIL CHANGE.
7. Drain the EV oil. Refer to OIL CHANGE.
8. Drain the front transaxle fluid. Refer to TRANSAXLE FLUID CHANGE.
9. Remove the following parts.
 
 
Engine Room LH
1. Disconnect all the connection destinations such as the engine control wiring harness around the engine mounting insulator (LH), and temporarily fix the engine control wiring harness to the engine assembly side.
cautionProtect the connector with a plastic bag, etc. to prevent foreign matter from adhering to it during work.
2. Remove the ground cable from the generator assembly.
 
 
Engine Room RH
1. Remove the A/C compressor assembly together with the hose from the bracket. Refer to Removal and Installation.
2. Tie the removed A/C compressor assembly in a place where it will not be a hindrance when removing and installing the assembly (which consists of the engine, the generator, the front motor and the front transaxle).
3. Disconnect the reservoir tank hose B from the reservior tank pipe. Refer to RADIATOR REMOVAL AND INSTALLATION.
 
 
Engine Room Center
1. Disconnect the radiator upper hose from the thermostat case and the radiator lower hose from the water inlet fitting. Refer to WATER HOSE AND WATER PIPE REMOVAL AND INSTALLATION.
2. Remove the radiator assembly. Refer to RADIATOR REMOVAL AND INSTALLATION.
3. Temporarily install the headlight support panel upper that was removed when the radiator was removed. Secure the A/C condenser assembly together with the A/C piping to the headlight support panel upper with a rope or the like.
4. Remove the front side air guide, the rear side air guide, the air guide lower and the air guide panel. Refer to Removal and Installation.
5. Disconnect the fuel-high pressure hose from the engine assembly. Refer to FUEL INJECTOR REMOVAL AND INSTALLATION.
6. Disconnect the heater hose from the engine assembly. Refer to Removal and Installation.
 
 
Vehicle Underbody
1. Remove the drive shafts (LH and RH). Refer to Removal and Installation.
2. Remove torque rod mounting bolts and , then remove the torque rod.
: Vehicle front
3. Remove the front suspension member. Refer to Removal and Installation.
 
 
Removal
1. Place EV battery cart (SST: MB992336), with a wooden board [around 15 mm (0.6 in) thick] placed over it, under the assembly (which consists of the engine, the generator, the front motor and the front transaxle assembly).
2. Place wooden blocks or pieces at the positions on the engine assembly shown in the figure (front: A/C bracket, rear: bolt head of the oil pan flange) to take the weight.
cautionAlways use wooden blocks or pieces to take the weight of the engine assembly at the specified position. If the weight is taken by the bottom of the oil pan, it will be deformed.
3. Lower the lift until the bottom of the transaxle case touches the wooden board, taking the weight of the assembly (which consists of the engine, the generator, the front motor and the front transaxle assembly).
4. Lower the lift to a position where the weight of the assembly (which consists of the engine, the generator, the front motor and the front transaxle assembly) does not take on the engine mounting insulator (LH and RH).
5. Remove the engine mounting stay (LH) mounting bolt , then remove the engine mounting insulator (LH) mounting bolts and .
: Vehicle front
6. Remove the engine mounting insulator (RH) mounting bolts , and .
: Vehicle front
7. Make sure that all the hoses and wiring harness connectors are disconnected.
8. Raise the body slightly with a lift and remove the engine mount insulator (LH and RH) from the gap between the assembly (which consists of the engine, the generator, the front motor and the front transaxle) and the body.
cautionBe careful not to bend the fuel-high pressure hose.
 
 
INSTALLATION
Note the following, and install in the reverse order of removal.
caution
  • Never allow engine oil to get on engine mounting insulator (LH and RH). Be careful not to damage engine mounting insulator (LH and RH).
  • Check that each mounting insulator (LH and RH) and torque rod are seated properly, and tighten mounting nuts and bolts.
  • For parts that are instructed in the mounting direction, check the front mark before mounting.
 
 
Preparation
1. Install the engine mounting insulator (LH) to the vehicle, and temporarily tighten the bolts before tightening to the specified torque, referring to the tightening method and the numerical order shown below:
Temporary tightening: 1
Final tightening (Specified torque): 2 → 3 → 4
: Vehicle front
2. Install the engine mounting insulator (RH) to the vehicle, and temporarily tighten the bolts, referring to the tightening method and the numerical order shown below:
Temporary tightening: 1 → 2 → 3
: Vehicle front
 
 
Installation
1. Lower the vehicle until the engine mounting insulator (RH) and the engine mounting insulator (LH) can be installed. To do so, be careful not to pinch the hoses or the connectors.
2. Install the engine mounting insulator (RH) to the engine assembly, and temporarily tighten the bolts before tightening to the specified torque, referring to the tightening method and the numerical order shown below:
Temporary tightening: 1
Final tightening (Specified torque): 2 → 3 → 4 → 5 → 6
: Vehicle front
3. Install the engine mounting insulator (LH) to the front motor assembly, and temporarily tighten the bolts before tightening to the specified torque, referring to the tightening method and the numerical order shown below:
Temporary tightening: 1
Final tightening (Specified torque): 2 → 3 → 4
: Vehicle front
4. Tighten the engine mounting insulator (RH) mounting bolts on the vehicle side to the specified torque.
Final tightening (Specified torque): 1 → 2 → 3
: Vehicle front
cautionCheck the engine mounting insulator (LH and RH) are not twisted.
5. Install the torque rod to the front suspension member and the front transaxle torque rod adapter, and temporarily tighten the bolts before tightening to the specified torque, referring to the tightening method and the numerical order shown below:
Temporary tightening: 1 → 2
Final tightening (Specified torque): 3 → 4
: Vehicle front
cautionCheck the torque rod is not twisted.