FixVault
Home › Lexus › 2007 › RX 400h FWD › Repair and Diagnosis › Engine Mechanical › Mechanical › Engine Mechanical › Engine Assembly › Removal

Engine Assembly: Removal

  1. PRECAUTION 

    (See REPAIR INSTRUCTION )

  2. REMOVE ENGINE ROOM SIDE LH COVER NO.2 
    1. Using a clip remover, remove the engine room side cover.
    Fig 1: Identifying Engine Room Side Cover
    G05276016Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE ENGINE ROOM COVER SIDE 
    1. Remove the 5 clips and engine room cover side.
      2. Fig 2: Locating Engine Room Cover Side Clips
      G05276017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. DISCHARGE FUEL SYSTEM PRESSURE 

    (See FUEL SYSTEM )

  5. REMOVE SERVICE PLUG GRIP  (See REMOVAL )
  6. REMOVE FRONT WHEELS 
  7. REMOVE ENGINE UNDER COVER NO.1 
    1. Remove the 6 bolts, 2 screws, 2 clips and engine under cover.
    Fig 3: Locating Engine Under Cover Bolts, Screws And Clips
    G05276018Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. SEPARATE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH 
    1. Remove the screw and separate the fender splash shield.
      2. Fig 4: Removing Fender Splash Shield
      G05276019Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. SEPARATE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  10. REMOVE FRONT FENDER APRON SEAL LH 
    1. Remove the 2 bolts, clip and fender apron seal LH.
      2. Fig 5: Locating Fender Apron Seal Bolts
      G05276020Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FRONT FENDER APRON SEAL RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  12. REMOVE ENGINE UNDER COVER NO.2 
    1. Remove the 2 bolts and engine under cover No.2.
  13. DRAIN COOLANT (for Engine)  (See COOLANT (for Engine) )
  14. DRAIN COOLANT (for Inverter)  (See COOLANT (for Inverter) )
  15. DRAIN ENGINE OIL  (See OIL AND OIL FILTER )
  16. DRAIN HYBRID TRANSAXLE FLUID  (See HYBRID TRANSAXLE SYSTEM )
  17. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  18. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  19. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  20. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See REMOVAL )
  21. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER 
    1. Separate the wire harness clamp and grommet (A).
      2. Fig 6: Locating Shock Absorber Nuts And Cowl Top Panel Bolts
      G05276021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 shock absorber nuts (B).
    3. Remove the 4 bolts, 2 nuts and cowl top panel sub-assembly.
    4. Install the 4 shock absorber nuts.

      Torque: 80 N*m (815 kgf*cm, 59 ft.*lbf) 

  22. REMOVE BATTERY 
    1. Remove the bolt and battery clamp.
    2. Remove the battery and battery tray.
  23. REMOVE BATTERY CARRIER SUB-ASSEMBLY 
    1. Remove the 5 bolts and battery carrier.
      2. Fig 7: Locating Battery Carrier Bolts
      G05200475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE COOL AIR INTAKE DUCT SEAL 
    1. Remove the 4 clips and cool air intake duct seal.
  25. REMOVE AIR CLEANER CAP W/ INLET 
    1. Remove the 2 bolts, 4 clamps and air cleaner cap w/ inlet.
      2. Fig 8: Locating Air Cleaner Cap W/Inlet Bolts And Clamps
      G05276023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the air cleaner filter element from the air cleaner case.
  26. REMOVE AIR CLEANER CASE W/RESONATOR  (See REMOVAL )
  27. REMOVE INVERTER BRACKET NO. 5  (See REMOVAL )
  28. REMOVE POWER STEERING ECU ASSEMBLY  (See REMOVAL )
  29. DISCONNECT CIRCUIT BREAKER SENSOR NO.1  (See REMOVAL )
  30. DISCONNECT ENGINE ROOM WIRE NO.2  (See REMOVAL )
  31. REMOVE INVERTER RESERVE TANK SUB-ASSEMBLY  (See REMOVAL )
  32. DISCONNECT WATER HOSE  (See REMOVAL )
  33. DISCONNECT POWER STEERING ECU BRACKET  (See REMOVAL )
  34. REMOVE INVERTER COVER  (See REMOVAL )
  35. REMOVE VERIFY THAT VOLTAGE OF W/ CONVERTER INVERTER ASSEMBLY IS 0V  (See REMOVAL )
  36. REMOVE ENGINE WIRE NO.4  (See REMOVAL )
  37. DISCONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR  (See REMOVAL )
  38. DISCONNECT MG ECU CONNECTOR  (See REMOVAL )
  39. DISCONNECT NO.3 WIRE FRAME  (See REMOVAL )
  40. INSTALL INVERTER COVER  (See REMOVAL )
  41. SEPARATE ENGINE ROOM RELAY BLOCK ASSEMBLY  (See REMOVAL )
  42. REMOVE INVERTER BRACKET NO.4  (See REMOVAL )
  43. REMOVE W/ CONVERTER INVERTER ASSEMBLY  (See REMOVAL )
  44. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY 
    1. Disconnect the connector.
    2. Remove the 2 bolts and separate the brake master cylinder reservoir.
    Fig 9: Locating Brake Master Cylinder Reservoir Bolts
    G05200477Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE RESERVOIR BRACKET 
    1. Disconnect the clamp.
    2. Remove the nut, 2 bolts and reservoir bracket.
    Fig 10: Locating Reservoir Bracket Nut And Bolts
    G05200478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE AIR CLEANER BRACKET 
    1. Remove the 2 bolts and air cleaner bracket.
      2. Fig 11: Locating Air Cleaner Bracket Bolts
      G05200479Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE ENGINE MOVING CONTROL ROD (See  REMOVAL  ) 
  48. REMOVE ENGINE MOUNTING STAY NO.2 RH (See  REMOVAL  ) 
  49. SEPARATE COMPRESSOR W/ MOTOR ASSEMBLY 
    1. Disconnect the 2 connectors.
    2. Remove the 3 bolts and compressor w/ motor assembly.

      HINT:

      Disconnect the compressor assembly together with the low-pressure and high-pressure hoses, then secure it to the vehicle side with rope.

    Fig 12: Locating Compressor W/Motor Assembly Bolts
    G05200480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE INVERTER BRACKET NO.1 
    1. Separate the 3 hose clamps.
    2. Remove the 4 bolts, harness clamp and inverter bracket.
    Fig 13: Locating Harness Clamp And Inverter Bracket Bolts
    G05200481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the nut and separate the control shaft lever from the position sensor.
    2. Remove the clip and disconnect the control cable from the bracket.
      Fig 14: Locating Control Shaft Lever Nut
      G05200482Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and separate the control cable from the transaxle.
      4. Fig 15: Locating Control Cable Bolt
      G05200483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. DISCONNECT FUEL VAPOR FEED HOSE 
  53. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO.1 
    1. Remove the EFI fuel pipe clamp.
      Fig 16: Removing EFI Fuel Pipe Clamp
      G05276031Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pinch the retainer as illustrated, then pull out the fuel tube connector from the pipe.
    NOTE:
    • Remove any dirt and foreign objects on the fuel tube connector before performing this work.
    • Do not allow any scratches or foreign objects on the parts when disconnecting, as the fuel tube connector has the O-rings that seal the pipe.
    • Perform this work by hand. Do not use any tools.
    • Do not forcibly bend, twist or turn the nylon tube.
    • Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.
    • If the fuel tube connector and pipe are stuck, push and pull them to release.
    Fig 17: Identifying Nylon Tube, Retainer And O-Ring
    G05276032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. DISCONNECT HEATER WATER INLET HOSE 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the heater water inlet hose.
      2. Fig 18: Identifying Heater Water Inlet Hose And Outlet Hose
      G05200486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. DISCONNECT HEATER WATER OUTLET HOSE 

    HINT:

    Disconnection of the heater water outlet hose is the same as for the heater water inlet hose.

  56. DISCONNECT RADIATOR HOSE INLET 
  57. DISCONNECT RADIATOR HOSE OUTLET 
  58. DISCONNECT OIL COOLER INLET TUBE SUB-ASSEMBLY (W/ OIL COOLER) 
    1. Using pliers, grip the claws of the clip and slide the clip to disconnect the oil cooler inlet tube.
      2. Fig 19: Locating Oil Cooler Inlet Tube Clip
      G05200487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. DISCONNECT OIL COOLER OUTLET TUBE SUB-ASSEMBLY (W/ OIL COOLER) 

    HINT:

    Disconnection of the oil cooler outlet tube is the same as for the oil cooler inlet tube.

  60. REMOVE HEATER WATER PUMP ASSEMBLY 
    1. Disconnect the connector.
    2. Remove the bolt and heater water pump.
      3. Fig 20: Locating Heater Water Pump Bolt
      G05200488Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. DISCONNECT WATER HOSE 
  62. REMOVE INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.2  (See REMOVAL )
  63. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY  (See REMOVAL )
  64. SEPARATE ENGINE WIRE 
    1. Disconnect the engine wire harness from the ECM and the junction block.
    2. Remove the 2 nuts and pull out the engine wire harness.
    3. Remove the body ground and connector.
  65. DISCONNECT WIRE HARNESS 
    1. Disconnect the power steering link connector and clamp.
    2. Remove the ground cable.
  66. REMOVE EXHAUST PIPE ASSEMBLY FRONT 
    1. Disconnect the heated oxygen sensor connector.
    2. Remove the 2 bolts, 2 nuts and exhaust pipe assembly front.
      3. Fig 21: Locating Exhaust Pipe Assembly Bolts And Nuts
      G05200489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 gaskets.
  67. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO.3 
    1. Disconnect the heated oxygen sensor connector.
    2. Remove the 2 bolts, 2 nuts and exhaust pipe sub-assembly front No.3.
      3. Fig 22: Locating Exhaust Pipe Sub-Assembly Bolts And Nuts
      G05200490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 gaskets.
  68. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH  (See REMOVAL )
  69. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  70. REMOVE FRONT AXLE HUB LH NUT  (See REMOVAL )
  71. REMOVE FRONT AXLE HUB RH NUT 

    HINT:

    Perform the same procedure as above on the opposite side.

  72. SEPARATE SPEED SENSOR FRONT LH  (See REMOVAL )
  73. SEPARATE SPEED SENSOR FRONT RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  74. SEPARATE TIE ROD END SUB-ASSEMBLY LH  (See REMOVAL )
  75. SEPARATE TIE ROD END SUB-ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  76. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH  (See REMOVAL )
  77. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  78. SEPARATE FRONT AXLE ASSEMBLY LH 
    1. Using a plastic hammer, separate the drive shaft from the axle hub.
      NOTE: Be careful not to damage the boot and speed sensor rotor.
  79. SEPARATE FRONT AXLE ASSEMBLY RH 

    HINT:

    Perform the same procedure as above on the opposite side.

  80. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY  (See REMOVAL )
  81. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
    2. Remove the 6 bolts and 2 nuts, then remove the frame side rail plates RH and LH.
      Fig 23: Locating Frame Side Rail Plates Bolts And Nuts
      G05200491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 bolts and 2 nuts, then remove the front suspension member brace rear RH and LH.
      4. Fig 24: Locating Front Suspension Member Brace Bolts And Nuts
      G05200492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Carefully remove the engine assembly from the vehicle.
    5. Install the No.2 engine hanger in the correct direction shown in the illustration.
      Fig 25: Identifying Engine Hanger
      G05276040Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

      HINT:

      Part No.

      ENGINE HANGER AND BOLT REFERENCE

      No.2 engine hanger 12282-20020
      Bolt 91621-60822
    6. Attach the engine sling and hang the engine assembly with the chain block.
  82. REMOVE ENGINE WIRE 
  83. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See  REMOVAL  ) 
  84. REMOVE MANIFOLD STAY (See  REMOVAL  ) 
  85. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (See  REMOVAL  ) 
  86. REMOVE HV TRANSAXLE MASS DAMPER 
    1. Remove the bolt and transaxle mass damper.
    Fig 26: Locating Transaxle Mass Damper Bolt
    G05276041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. REMOVE FRONT FRAME ASSEMBLY 
    1. Remove the 2 nuts and separate the engine mounting insulators RH and LH.
      Fig 27: Locating Engine Mounting Insulators Nuts
      G05129362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut and separate engine mounting insulator FR.
      Fig 28: Locating Engine Mounting Insulator FR Nut
      G05200496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and separate the engine mounting insulator RR.
      4. Fig 29: Locating Engine Mounting Insulator RR Bolts
      G05200497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH  (See REMOVAL )
  89. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH  (See REMOVAL )
  90. REMOVE FLYWHEEL HOUSING UNDER COVER  (See REMOVAL )
  91. REMOVE ENGINE MOUNTING BRACKET FRONT  (See REMOVAL )
  92. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY  (See REMOVAL )
  93. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY (See  REMOVAL  ) 
  94. REMOVE FLYWHEEL SUB-ASSEMBLY (See  REMOVAL  ) 
  95. INSTALL ENGINE STAND 
  96. REMOVE ENGINE HANGER NO.2 
    1. Remove the 2 bolts and engine hanger No.2.
      2. Fig 30: Identifying Engine Hanger
      G05238785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  97. REMOVE EMISSION CONTROL VALVE SET  (See REMOVAL )
  98. REMOVE INTAKE AIR SURGE TANK  (See REMOVAL )
  99. REMOVE INTAKE MANIFOLD (See  REMOVAL  ) 
  100. REMOVE WATER OUTLET (See  REMOVAL  ) 
  101. REMOVE IGNITION COIL ASSEMBLY 
  102. REMOVE MANIFOLD CONVERTER INSULATOR NO.3 (See  REMOVAL  ) 
  103. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See  REMOVAL  ) 
  104. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2 (See  REMOVAL  ) 
  105. REMOVE MANIFOLD STAY NO.2 
    1. Remove the 2 bolts and manifold stay No.2.
  106. REMOVE ENGINE MOUNTING BRACKET REAR 
    1. Remove the 3 bolts and engine mounting bracket rear.
    Fig 31: Locating Engine Mounting Bracket Bolts (Rear)
    G05200499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  107. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and engine mounting bracket RH.
    Fig 32: Locating Engine Mounting Bracket Bolts (RH)
    G05200500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  108. REMOVE ENGINE MOUNTING STAY BRACKET 
    1. Remove the bolt, nut and engine mounting stay bracket.
    Fig 33: Locating Engine Mounting Stay Bracket Bolt And Nut
    G05200501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  109. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 
    1. Remove the 4 bolts and compressor mounting bracket.
    Fig 34: Locating Compressor Mounting Bracket Bolts
    G05200502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  110. REMOVE INTAKE AIR CONNECTOR BRACKET NO.2 
    1. Remove the 2 bolts and intake air connector bracket No.2.
      2. Fig 35: Locating Intake Air Connector Bracket Bolts
      G05200503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  111. REMOVE WATER INLET PIPE  (See REMOVAL )
  112. REMOVE WATER INLET  (See REMOVAL )
  113. REMOVE THERMOSTAT 
  114. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Using a deep socket wrench 24 mm, remove the oil pressure switch.
      2. Fig 36: Removing Oil Pressure Switch
      G05200504Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  115. REMOVE KNOCK CONTROL SENSOR  (See REMOVAL )
  116. REPLACE PARTIAL ENGINE ASSEMBLY 
About FixVault