RM3660EC _51 Engine / Hybrid System _080726 8ZR-FXE ENGINE MECHANICAL _0391619 ENGINE ASSEMBLY A

8ZR-FXE ENGINE MECHANICAL ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during engine assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
*: The vehicle height changes because of tire replacement.
Replacement of ECM	Vehicle Identification Number (VIN) or frame number registration	DTC stored	(202304,999999,_51,_080778,_0393982,RM100000002BDLH,)
	ECU configuration	-	(202304,999999,_V1,_143216,_0598316,RM100000002B3MK,)
	Update ECU security key	Vehicle Control History (RoB) are stored	(202304,999999,_V1,_143216,_0598316,RM100000002B3ML,)
	Perform Total Short Trip Estimate Registration	-	(202304,999999,_51,_080778,_0393982,RM100000002BDLH,)
Replacement of inverter with converter assembly	ECU configuration	-	(202304,999999,_V1,_143216,_0598316,RM100000002B3MK,)
Replacement of inverter with converter assembly	Resolver learning	· DTCs are stored · Slight vibration at a vehicle speed of 5 km/h (3 mph) or less · Shock or vibration during acceleration	(202304,999999,_51,_080773,_0600292,RM100000002BBW3,)
· Replacement of throttle body assembly · Replacement of engine assembly · Gas leak from exhaust system is repaired	Inspection after repair	· Poor idle, etc. · Engine start function, etc.	(202304,999999,_51,_080778,_0393982,RM100000002BDLI,)
Replacement of hybrid vehicle transaxle assembly	· Resolver learning · Initialize resolver	· DTCs are stored · Slight vibration at a vehicle speed of 5 km/h (3 mph) or less	(202304,999999,_51,_080773,_0600292,RM100000002BBW3,)
· Tires · Suspension parts	Rear television camera assembly optical axis (Back camera position setting)*	Parking Assist Monitor System	(202304,999999,_56,_080754,_0596561,RM100000002AX0C,)
· Tires · Suspension parts	Parking assist ECU initialization	Panoramic View Monitor System	(202307,999999,_56,_080754,_0612151,RM100000002CL9H,)
Front wheel alignment adjustment	1. Perform "Reset Memory" 2. Perform "Calibration"	· DTCs are stored · ABS warning light illuminates · Brake system warning light (yellow indicator) illuminates · Slip indicator light illuminates · Electronically controlled brake system disabled or malfunctions	(202304,999999,_54,_080770,_0392591,RM100000002B671,)

CAUTION:

2.219,0.813 2.646,0.813 false 2.698,0.729 3.01,0.927 0.313,0.198 10 false *a

*a	An Object Exceeding Weight Limit of Engine Lifter

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when vehicle is driven
Effect/Inoperative Function when Necessary Procedure not Performed	Necessary Procedure	Link
Front Camera System	Drive the vehicle straight ahead at 15 km/h (9 mph) or more for 1 second or more.	(202304,999999,_95,_139716,_0584193,RM1000000029F4C,)

PROCEDURE

Hide Display 1. PRECAUTION

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION201906,999999,_V1,_080724,_0393249,RM100000001HWSK,

Hide Display 2.RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>REPLACEMENT202304,999999,_58,_080733,_0393725,RM100000002B1HP_01_0001,

Hide Display 3. DISCHARGE FUEL SYSTEM PRESSURE

Click hereEngine / Hybrid System>8ZR-FXE (FUEL)>FUEL SYSTEM>PRECAUTION202304,999999,_51,_080749,_0393854,RM10000000293GY,

Hide Display 4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

Hide Display 5.SECURE STEERING WHEEL

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR>REMOVAL202307,999999,_55,_080765,_0392687,RM100000002CQYW_01_0124,

Hide Display 6.REMOVE FRONT WHEELS

Click hereGeneral>MAINTENANCE>TIRE AND WHEEL>REMOVAL202307,999999,_V1,_080956,_0392691,RM100000002CWK9,

Hide Display 51410 7.REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

Remove the 4 bolts.

Remove the 10 clips and No. 1 engine under cover assembly from the vehicle.

Hide Display 51444A 8.REMOVE REAR ENGINE UNDER COVER LH

Remove the screw.

Remove the 4 clips and rear engine under cover LH from the vehicle.

Hide Display 51443C 9.REMOVE REAR ENGINE UNDER COVER RH

Remove the screw.

Remove the 4 clips and rear engine under cover RH from the vehicle.

Hide Display 10.DRAIN ENGINE OIL

Click hereGeneral>MAINTENANCE>8ZR-FXE OIL AND OIL FILTER>REPLACEMENT202304,999999,_V1,_080956,_0392374,RM100000002BETD_02_0018,

Hide Display 11.DRAIN ENGINE COOLANT (for Engine)

Click hereGeneral>MAINTENANCE>8ZR-FXE COOLANT (for Engine Coolant)>REPLACEMENT202304,999999,_V1,_080956,_0392619,RM100000002BDID_01_0020,

Hide Display 12.DRAIN HYBRID TRANSAXLE FLUID

Click hereDrivetrain>PA10/PB10 (HYBRID TRANSMISSION / TRANSAXLE)>HYBRID TRANSAXLE FLUID>ADJUSTMENT202307,999999,_52,_138496,_0583540,RM100000002CIQ7_01_0004,

Hide Display 16296 13.DISCONNECT NO. 8 WATER BY-PASS HOSE

Slide the clip and disconnect the No. 8 water by-pass hose from the No. 4 water by-pass hose.

Hide Display 53289A 14.REMOVE RADIATOR SUPPORT OPENING COVER

for TFTM Made:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for TFTM Made)>REMOVAL202307,999999,_59,_080736,_0392548,RM100000002CH8T_01_0035,

for GTMC Made:

Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for GTMC Made)>REMOVAL202307,999999,_59,_080736,_0392547,RM100000002CHFA_01_0036,

Hide Display 17752 15.REMOVE INLET NO. 2 AIR CLEANER

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392072,RM100000002B0QN_01_0157,

Hide Display 22210 16.REMOVE THROTTLE BODY ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (ENGINE CONTROL)>THROTTLE BODY>REMOVAL202304,999999,_51,_080778,_0392133,RM10000000295TV,

Hide Display 17801 17.REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392072,RM100000002B0QN_01_0158,

Hide Display 17701 18.REMOVE AIR CLEANER CASE SUB-ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392072,RM100000002B0QN_01_0159,

Hide Display 17771A 19.REMOVE AIR CLEANER BRACKET

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392072,RM100000002B0QN_01_0160,

Hide Display 17751 20.REMOVE INLET NO. 1 AIR CLEANER

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>INTAKE MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392072,RM100000002B0QN_01_0145,

Hide Display G9200 21.REMOVE INVERTER WITH CONVERTER ASSEMBLY

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>8ZR-FXE INVERTER WITH CONVERTER>REMOVAL202304,999999,_51,_080773,_0392172,RM100000002B8GJ,

Hide Display 33820B 22.DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

1.698,2.469 1.99,2.219 false 2.031,2.125 2.333,2.333 0.302,0.208 10 false *a 2.125,3.01 2.438,3.219 0.313,0.208 10 false *b

*a	Clip
*b	45° to 60°

While disengaging the clip as shown in the illustration, disconnect the transmission control cable assembly from the transmission control shaft lever together with the clip.

Remove the clip and disconnect the transmission control cable assembly from the No. 1 transmission control cable bracket.

Disconnect the transmission control cable assembly from the transmission control cable support.

Remove the bolt and disconnect the transmission control cable assembly from the engine assembly.

Hide Display 16571C 23.DISCONNECT NO. 1 RADIATOR HOSE

Slide the clip and disconnect the No. 1 radiator hose from the water outlet.

Hide Display 16572D 24.DISCONNECT NO. 2 RADIATOR HOSE

Slide the clip and disconnect the No. 2 radiator hose from the water inlet sub-assembly.

Hide Display 87245 25.DISCONNECT INLET HEATER WATER HOSE

Slide the clip and disconnect the inlet heater water hose.

Hide Display 87246 26.DISCONNECT OUTLET HEATER WATER HOSE

Slide the clip and disconnect the outlet heater water hose.

Hide Display 23829A 27.DISCONNECT FUEL VAPOR FEED HOSE

Slide the clip and disconnect the fuel vapor feed hose from the fuel vapor feed pipe.

Hide Display 23901 28.DISCONNECT FUEL TUBE SUB-ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (FUEL)>FUEL INJECTOR>REMOVAL202304,999999,_51,_080749,_0393855,RM10000000293H4_01_0091,

Hide Display 88703 29.DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for 8ZR-FXE)>REMOVAL202304,999999,_58,_080733,_0393735,RM100000002BH20_01_0210,

Hide Display 88704 30.DISCONNECT SUCTION HOSE SUB-ASSEMBLY

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for 8ZR-FXE)>REMOVAL202304,999999,_58,_080733,_0393735,RM100000002BH20_01_0211,

Hide Display 82127D 31.DISCONNECT NO. 7 ENGINE WIRE

Remove the bolt.

Disengage the 2 clamps and disconnect the No. 7 engine wire from the hybrid vehicle transaxle assembly.

Hide Display 45259A 32.REMOVE COLUMN HOLE COVER SILENCER SHEET

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>REMOVAL202304,999999,_55,_080762,_0391589,RM100000002BCU5_01_0135,

Hide Display 45260 33.SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click hereSteering>STEERING COLUMN>STEERING COLUMN ASSEMBLY>REMOVAL202304,999999,_55,_080762,_0391589,RM100000002BCU5_01_0126,

Hide Display 45025D 34.SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR>REMOVAL202307,999999,_55,_080765,_0392687,RM100000002CQYW_01_0013,

Hide Display 58166A 35.REMOVE FRONT FLOOR COVER LH

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>EXHAUST MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392073,RM100000002B0QV_01_0153,

Hide Display 58165C 36.REMOVE FRONT FLOOR COVER RH

HINT:: Use the same procedure as for the LH side.

Hide Display 57533B 37.REMOVE FRONT FLOOR CENTER BRACE

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>EXHAUST MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392073,RM100000002B0QV_01_0155,

Hide Display 17410 38.REMOVE FRONT EXHAUST PIPE ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>EXHAUST MANIFOLD>REMOVAL202304,999999,_51,_080790,_0392073,RM100000002B0QV_01_0130,

Hide Display 39.REMOVE FRONT DRIVE SHAFT ASSEMBLY

for TFTM Made:

Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>FRONT DRIVE SHAFT ASSEMBLY (for TFTM Made)>REMOVAL202307,999999,_52,_080779,_0392672,RM100000002CL7W,

for GTMC Made:

Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>FRONT DRIVE SHAFT ASSEMBLY (for GTMC Made)>REMOVAL202307,999999,_52,_080779,_0392671,RM100000002CL92,

Hide Display 51108A 40.REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

Click hereSuspension>FRONT SUSPENSION>FRONT SUSPENSION MEMBER>REMOVAL202307,999999,_53,_080764,_0392686,RM100000002CQYS_01_0197,

Hide Display 51107A 41.REMOVE REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

HINT:: Use the same procedure as for the LH side.

Hide Display 42.REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

Set the engine assembly with transaxle on an engine lifter.

NOTICE:: ·

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.

Remove the 2 bolts and nut and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.

Remove the 3 bolts and nut and separate the engine mounting insulator LH from the hybrid vehicle transaxle assembly.

Remove the bolt and No. 2 engine mounting stay LH.

Remove the 4 bolts to separate the front suspension crossmember sub-assembly from the vehicle.

Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.

NOTICE:: ·

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.

Hide Display 43.REMOVE WIRE HARNESS CLAMP BRACKET

Disengage the 3 clamps.

Remove the bolt and wire harness clamp bracket from the cylinder head sub-assembly.

Hide Display 44.INSTALL ENGINE HANGERS

1.76,0.885 2.167,0.885 true 1.885,3.417 2.292,3.417 true 1.365,4.365 1.552,4.365 1.552,4.365 1.792,3.875 true 1.281,2.063 1.469,2.063 1.469,2.063 1.708,1.573 true 2.188,0.813 2.5,1.01 0.313,0.198 10 true *1 2.323,3.333 2.635,3.531 0.313,0.198 10 true *2 1.042,2.01 1.271,2.219 0.229,0.208 10 true *a 1.094,4.292 1.344,4.49 0.25,0.198 10 true *a

*1	No. 1 Engine Hanger
*2	No. 2 Engine Hanger
*a	Bolt

Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts.

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

HINT:

No. 1 Engine Hanger	12281-0T020
No. 2 Engine Hanger	12282-0T020
Bolt	90105-C0097

Using an engine sling device and engine lifter, secure the engine assembly with transaxle.

NOTICE:: ·

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.

Hide Display 12372A 45.REMOVE ENGINE MOUNTING INSULATOR LH

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

Disengage the 2 clamps.

Remove the 4 bolts, nut and engine mounting insulator LH from the vehicle.

Hide Display 12305 46.REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

HINT:: Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

Remove the 2 bolts and No. 2 earth wire from the engine mounting insulator sub-assembly RH and vehicle.

Remove the bolt, nut and disconnect the air conditioner tube and accessory assembly.

Remove the 2 bolts, nut and engine mounting insulator sub-assembly RH from the vehicle.

Hide Display 88370 47.REMOVE COMPRESSOR WITH MOTOR ASSEMBLY

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for 8ZR-FXE)>REMOVAL202304,999999,_58,_080733,_0393735,RM100000002BH20_01_0199,

Hide Display 28193 48.REMOVE STARTER HOLE INSULATOR

Click hereDrivetrain>PA10/PB10 (HYBRID TRANSMISSION / TRANSAXLE)>PA10 HYBRID VEHICLE TRANSAXLE>REMOVAL202307,999999,_52,_138496,_0583538,RM100000002CW48_01_0317,

Hide Display 11363A 49.REMOVE FLYWHEEL HOUSING SIDE COVER

Click hereDrivetrain>PA10/PB10 (HYBRID TRANSMISSION / TRANSAXLE)>PA10 HYBRID VEHICLE TRANSAXLE>REMOVAL202307,999999,_52,_138496,_0583538,RM100000002CW48_01_0302,

Hide Display 82121 50.REMOVE ENGINE WIRE

Disconnect all the clamps and connectors and remove the engine wire from the engine assembly with transaxle.

Hide Display 51.REMOVE ENGINE ASSEMBLY

Click hereDrivetrain>PA10/PB10 (HYBRID TRANSMISSION / TRANSAXLE)>PA10 HYBRID VEHICLE TRANSAXLE>REMOVAL202307,999999,_52,_138496,_0583538,RM100000002CW48_01_0310,

Hide Display 31270 52.REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (ENGINE MECHANICAL)>REAR CRANKSHAFT OIL SEAL>REMOVAL202307,999999,_51,_080726,_0391618,RM100000002CWTR_03_0353,

Hide Display 13405 53.REMOVE FLYWHEEL SUB-ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (ENGINE MECHANICAL)>REAR CRANKSHAFT OIL SEAL>REMOVAL202307,999999,_51,_080726,_0391618,RM100000002CWTR_03_0342,

Hide Display 54.INSTALL ENGINE ASSEMBLY TO ENGINE STAND

Install the engine assembly to an engine stand.

Hide Display 55.REMOVE ENGINE HANGERS

Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.