ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

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.

Tech Tips

Perform "Inspection After Repair" after replacing the engine assembly.

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PROCEDURE


  1. INSTALL ENGINE HANGERS

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  2. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  3. INSTALL FLYWHEEL SUB-ASSEMBLY

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  4. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY

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  5. INSTALL ENGINE ASSEMBLY

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  6. INSTALL ENGINE WIRE


    1. Connect all the connectors and clamps, and install the engine wire to the engine assembly with transaxle.

  7. INSTALL FLYWHEEL HOUSING SIDE COVER

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  8. INSTALL STARTER HOLE INSULATOR

    Click here

  9. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  10. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

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


    1. A005MNOC03
      *a Temporarily Tighten

      Temporarily install the engine mounting insulator sub-assembly RH to the vehicle.

    2. Install the 2 bolts and nut in the order shown in the illustration.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

    3. Connect the air conditioner tube and accessory assembly to the engine mounting insulator sub-assembly RH with the bolt and nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    4. Install the No. 2 earth wire to the engine mounting insulator sub-assembly RH and vehicle body with the 2 bolts.

      Torque:
      10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

  11. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A005MUDC03
      *a Temporarily Tighten

      Temporarily install the engine mounting insulator LH to the vehicle.

    2. Install the 4 bolts and nut in the order shown in the illustration.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

  12. REMOVE ENGINE HANGER

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  13. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket with the bolt.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    2. Engage the 3 clamps.

  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front suspension crossmember sub-assembly level, set an engine lifter underneath the engine assembly with transaxle and front suspension crossmember sub-assembly.

      Note


      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle horizontal.

      • 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 oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

    2. Operate the engine lifter and install the engine assembly with transaxle to the vehicle.

      CAUTION:

      Do not raise the engine assembly with transaxle more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

      Note


      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

      • While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.

    3. Connect the front suspension crossmember sub-assembly to the vehicle with the 6 bolts.

      Torque:
      141 N*m  { 1438 kgf*cm, 104 ft.*lbf }
    4. A005O1UC01
      *a Adhesive

      Apply adhesive to 2 or 3 threads of bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    5. Install the No. 2 engine mounting stay LH with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    6. Install the engine mounting insulator LH to the hybrid vehicle transaxle assembly with the 3 bolts and nut.

      Torque:
      Bolt
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }
      Nut
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    7. Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 2 bolts and nut.

      Torque:
      Bolt
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }
      Nut
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

  15. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

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  16. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  17. INSTALL FRONT DRIVE SHAFT ASSEMBLY

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  18. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

    Click here

  19. INSTALL FRONT FLOOR CENTER BRACE

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  20. INSTALL FRONT FLOOR COVER LH

    Click here

  21. INSTALL FRONT FLOOR COVER RH

    Tech Tips

    Use the same procedure as for the LH side.

  22. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

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  23. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  24. INSTALL COLUMN HOLE COVER SILENCER SHEET

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  25. CONNECT NO. 3 ENGINE WIRE


    1. A005MYUC01
      *a Bolt (A)
      *b Bolt (B)

      Connect the No. 3 engine wire to hybrid vehicle transaxle assembly with the 2 bolts.

      Torque:
      Bolt (A)
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt (B)
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

    2. Engage the clamp.

  26. CONNECT SUCTION HOSE SUB-ASSEMBLY

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  27. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

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  28. CONNECT OUTLET NO. 1 HYBRID WATER PUMP HOSE


    1. Connect the outlet No. 1 hybrid water pump hose to the motor cooling cooler and slide the clip to secure it.

  29. CONNECT INLET HYBRID RADIATOR HOSE


    1. Connect the inlet hybrid radiator hose to the motor cooling cooler and slide the clip to secure it.

  30. CONNECT FUEL TUBE SUB-ASSEMBLY

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  31. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the No. 1 fuel vapor feed hose to the fuel vapor feed pipe and slide the clip to secure it.

  32. CONNECT INLET HEATER WATER HOSE A


    1. Connect the inlet heater water hose A to the EGR pipe with cooler sub-assembly and slide the clip to secure it.

  33. CONNECT OUTLET HEATER WATER HOSE


    1. Connect the outlet heater water hose to the No. 1 water by-pass pipe and slide the clip to secure it.

  34. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the water inlet sub-assembly and slide the clip to secure it.

  35. CONNECT NO. 3 RADIATOR HOSE


    1. Connect the No. 3 radiator hose to the water outlet and slide the clip to secure it.

    2. Install the 2 bolts to the hybrid vehicle transaxle assembly.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  36. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Connect the transmission control cable assembly to the cylinder head cover sub-assembly with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. Install the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

    3. Install the transmission control cable assembly to the control shaft lever with the nut.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  37. INSTALL INVERTER WITH CONVERTER ASSEMBLY

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  38. INSTALL NO. 1 AIR CLEANER INLET

    Click here

  39. INSTALL AIR CLEANER BRACKET

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  40. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  41. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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  42. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  43. INSTALL NO. 2 AIR CLEANER INLET

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  44. INSTALL RADIATOR COVER

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  45. CONNECT NO. 8 WATER BY-PASS HOSE


    1. Connect the No. 8 water by-pass hose to the No. 2 water by-pass hose assembly and slide the clip to secure it.

  46. ADD ENGINE OIL

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  47. ADD HYBRID TRANSAXLE FLUID

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  48. ADD ENGINE COOLANT (for Engine)

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  49. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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  50. CHECK ENGINE OIL LEVEL

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  51. INSPECT HYBRID TRANSAXLE FLUID

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  52. INSPECT SHIFT LEVER POSITION

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  53. ADJUST SHIFT LEVER POSITION

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  54. INSPECT FOR COOLANT LEAK (for Inverter)

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  55. INSPECT FOR COOLANT LEAK (for Engine)

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  56. WARM UP COMPRESSOR


    1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

      Note

      To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing any air conditioning system lines (including the compressor).

  57. INSPECT FOR REFRIGERANT LEAK

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  58. INSPECT FOR FUEL LEAK

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  59. INSPECT FOR OIL LEAK

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  60. INSPECT FOR EXHAUST GAS LEAK

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  61. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH to the vehicle with the 6 clips.

  62. INSTALL REAR ENGINE UNDER COVER RH


    1. Install the rear engine under cover RH to the vehicle with the 6 clips.

  63. INSTALL NO. 1 ENGINE UNDER COVER


    1. A005NX5C02
      *1 Bolt

      Install the No. 1 engine under cover to the vehicle with the 4 bolts, 4 screws and 4 clips.

      Torque:
      Bolt
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  64. INSTALL FRONT WHEELS

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  65. INSPECT IGNITION TIMING

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  66. INSPECT ENGINE IDLE SPEED

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  67. INSPECT CO/HC

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  68. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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  69. CHECK SPEED SENSOR SIGNAL

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