REMOVAL AND INSTALLATION



caution When the engine assembly is replaced, initialise the learned value using M.U.T.-III (Refer to GROUP 00 - Precautions before Service, and Initialisation Procedure of MPI Engine Learned Value ).
Pre-removal Operation
  • Fuel Line Pressure Reduction (Refer to GROUP 13E - On-vehicle Service, How to Reduce Pressurized Fuel Lines ).
  • Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Removal (Refer to GROUP 51 - Under Cover ).
  • Air Cleaner Intake Hose and Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Engine Coolant Draining (Refer to GROUP 14A - On-vehicle Service, Engine Coolant Replacement ).
  • Front Transaxle Fluid Draining (Refer to GROUP 22D - Front Transaxle, On-vehicle Service )).
  • Motor Oil Draining (Refer to GROUP 14B - On-vehicle Service <Oil Cooling System>, Oil Change ).
  • Motor Coolant Draining (Refer to GROUP 14B - On-vehicle Service <Water Cooling System>, Motor Coolant Change ).

Post-installation Operation
  • Motor Coolant Refilling (Refer to GROUP 14B - On-vehicle Service <Water Cooling System>, Motor Coolant Change ).
  • Motor Oil Refilling (Refer to GROUP 14B - On-vehicle Service <Oil Cooling System>, Oil Change ).
  • Front Transaxle Fluid Refilling (Refer to GROUP 22D - Front Transaxle, On-vehicle Service ).
  • Engine Coolant Refilling (Refer to GROUP 14A - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Air Cleaner Intake Hose and Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner ).
  • Fuel Leak Check.
  • Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Installation (Refer to GROUP 51 - Under Cover ).





Removal steps


·
Exhaust front pipe (Refer to GROUP 15 - Exhaust Pipe and Main Muffler ).


·
Brake electric vacuum pump assembly and brake electric vacuum pump assembly mounting bracket (Refer to GROUP 35A - Brake Electric Vacuum Pump ).
<<A>>

·
A/C compressor assembly (Refer to GROUP 55 - Compressor Assembly ).


1.
Earth cable connection


·
Accessory bracket (Refer to GROUP 11H - Inlet Manifold And Fuel System ).


·
FPDU (Refer to GROUP 54D - Inverter <Front> ).


·
FPDU upper bracket assembly


2.
Control wiring harness connection


3.
Engine-ECU connector connection


4.
Earth cable connection


·
Heater hose connection (Refer to GROUP 14A - Water Hose and Water Pipe ).


·
Radiator upper hose connection (Refer to GROUP 14A - Water Hose and Water Pipe ).


·
Radiator lower hose connection (Refer to GROUP 14A - Thermostat ).


·
Throttle body water feed hose connection


·
Fuel high-pressure hose connection


·
Front suspension crossmember
<<B>>
>>A<<
·
Transmission mounting bracket (Refer to GROUP 32 - Transmission Mounting ).
<<B>>
>>A<<
·
Engine mounting bracket (Refer to GROUP 32 - Engine Mounting ).
<<C>>
>>A<<
5.
Engine, alternator, front motor and front transaxle assembly


·
Generator (Refer to GROUP 54D - Generator ).


·
Front motor (power unit) assembly (Refer to GROUP 54D - Motor (Power Unit) <Front> ).


·
Front transaxle (Refer to GROUP 22D - Transaxle assembly ).

REMOVAL SERVICE POINTS



<<A>> A/C COMPRESSOR ASSEMBLY REMOVAL


1.Remove the A/C compressor from the bracket without disconnecting the wiring harness wires and the connectors.
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).

<<B>> TRANSMISSION MOUNTING BRACKET/ENGINE MOUNTING BRACKET REMOVAL


caution When you support the assembly (which consists of the engine, the generator, the front motor and the front transaxle), the weight of the assembly must not be taken by the oil pan only. Always use wooden blocks or pieces and then place the oil pan flange on them. Never put the oil pan directly on a floor as it will be deformed.

1.Place a cart below the assembly.
2.Raise the vehicle to take the weight of the assembly off the transmission mounting bracket and the engine mounting bracket.
3.Remove the nuts and bolts securing the transmission mounting bracket and the engine mounting bracket.
4.Remove the transmission mounting bracket and the engine mounting bracket.

<<C>> ENGINE, GENERATOR, FRONT MOTOR AND FRONT TRANSAXLE ASSEMBLY REMOVAL


1.Make sure that all the hoses and wiring harness connectors are disconnected.

2.
caution Be careful not to bend the fuel high pressure hose.
Raise the body slowly with a lift, and remove the assembly.

INSTALLATION SERVICE POINTS



>>A<< ENGINE, GENERATOR, FRONT MOTOR AND FRONT TRANSAXLE ASSEMBLY INSTALLATION



1.Place the assembly on the cart below the lifted vehicle.

2.Raise the vehicle until the engine mounting bracket and the transmission mounting bracket can be installed. To do so, be careful not to pinch the hoses or the connectors.
3.Install the engine mounting bracket and the transmission mounting bracket.