ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transmission is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed.

Therefore, always follow the instructions listed in the repair manual when performing this procedure.

PROCEDURE


  1. INSTALL ENGINE HANGER

    Click here

  2. REMOVE ENGINE STAND


    1. Attach an engine sling device and hang the engine with a chain block.

      Note

      Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    2. Lift the engine and remove it from the engine stand.

      Note

      With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

    3. Place the engine onto a work bench.

  3. INSTALL REAR ENGINE MOUNTING INSULATOR

    Click here

  4. INSTALL REAR ENGINE MOUNTING MEMBER


    1. B004BSH

      Install the rear engine mounting member to the rear engine mounting insulator with the 3 nuts.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  5. INSTALL FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

    Only perform this procedure when replacement of the engine mounting insulator is necessary.


    1. Install the 2 front engine mounting insulators with the 2 bolts

      Torque:
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }

  6. CONNECT FRONT FRAME CROSSMEMBER SUB-ASSEMBLY


    1. Install the front frame crossmember sub-assembly to the enine assembly with the 2 nuts

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }

  7. INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

  8. INSTALL TRANSMISSION INPUT DAMPER COVER ASSEMBLY

    Click here

  9. INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here

  10. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  11. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  12. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  13. CONNECT AIR FUEL RATIO SENSOR

    Click here

  14. INSTALL NO. 1 EGR PIPE

    Click here

  15. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the engine oil level dipstick guide.

    2. Apply a light coat of engine oil to the O-ring.

    3. Push in the engine oil level dipstick guide end into the guide hole.

    4. Install the engine oil level dipstick guide with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  16. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  17. INSTALL ENGINE AND TRANSMISSION ASSEMBLY


    1. B004CQTC01
      B0049X5 Place Wooden Block or Plate Attachments

      Set the engine on an engine lifter.

      Note


      • Place wooden blocks or plate lift attachments so that the engine is level.

      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

      • Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.

    2. Operate the engine lifter and install the engine and transmission assembly to the vehicle.

      Note

      Make sure that the engine is clear of all wiring and hoses.

    3. B004ANRC01
      B004C4F Bolt
      B004ANI Nut

      Install the engine and transmission assembly to the vehicle with the 2 bolts and 2 nuts.

      Torque:
      170 N*m  { 1734 kgf*cm, 125 ft.*lbf }
    4. B0049V7

      Install the rear engine mounting member with the 6 bolts.

      Torque:
      34.7 N*m  { 354 kgf*cm, 26 ft.*lbf }

    5. Remove the 4 bolts and 2 engine hangers.

  18. INSTALL NO. 2 GROUND WIRE


    1. B004COQ

      Connect the No. 2 ground wire.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  19. CONNECT NO. 2 PARKING LOCK RELEASE CABLE ASSEMBLY


    1. B004BWKC01
      *1 Parking Lock Release Lever Assembly Cable End
      *2 No. 2 Parking Lock Release Cable Assembly Cable End

      Connect the parking lock release lever assembly cable end to the No. 2 parking lock release cable assembly cable end.

    2. B004BYTC02
      *1 Cover
      B004ANI Arrow
      B004B1M Connect

      Attach the 2 claws and connect the cover to the No. 2 parking lock release cable assembly as shown in the illustration.

  20. INSTALL REAR LOWER ARM MOUNTING REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  21. INSTALL REAR LOWER ARM MOUNTING REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  22. TEMPORARILY TIGHTEN STEERING KNUCKLE LH


    1. B004CK0

      Install the steering knuckle LH with the 2 bolts and 2 nuts.

  23. TEMPORARILY TIGHTEN STEERING KNUCKLE RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  24. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  25. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  26. CONNECT TIE ROD ASSEMBLY LH

    Click here

  27. CONNECT TIE ROD ASSEMBLY RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  28. INSTALL FRONT DISC BRAKE DUST COVER LH

    Click here

  29. INSTALL FRONT DISC BRAKE DUST COVER RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  30. INSTALL FRONT DISC LH

    Click here

  31. INSTALL FRONT DISC RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  32. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY LH

    Click here

  33. INSTALL FRONT DISC BRAKE CALIPER ASSEMBLY RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  34. CONNECT FRONT HEIGHT CONTROL SENSOR SUB-ASSEMBLY LH

    Click here

  35. CONNECT FRONT HEIGHT CONTROL SENSOR SUB-ASSEMBLY RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  36. CONNECT FRONT SKID CONTROL SENSOR WIRE LH

    Click here

  37. CONNECT FRONT SKID CONTROL SENSOR WIRE RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  38. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

    Click here

  39. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  40. INSPECT AND ADJUST NO. 2 AND NO. 3 JOINT ANGLE

    Click here

  41. FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING ASSEMBLY

    Click here

  42. INSTALL NO. 2 FUEL TANK PROTECTOR

    Click here

  43. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR

    Click here

  44. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  45. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

  46. INSTALL FRONT FENDER SEAL LH

    Click here

  47. INSTALL FRONT FENDER SEAL RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  48. INSTALL FRONT FLOOR COVER LH

    Click here

  49. INSTALL FRONT FLOOR COVER RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  50. INSTALL REAR FLOOR SIDE MEMBER COVER LH

    Click here

  51. INSTALL REAR FLOOR SIDE MEMBER COVER RH

    Tech Tips

    Remove the RH side following the same procedure as for the LH side.

  52. INSTALL REAR FRAME RAIL SUB-ASSEMBLY


    1. B004AG9C01
      *a Bolt A
      *b Bolt B

      Install the rear frame rail sub-assembly LH and rear frame rail sub-assembly RH with the 6 bolts and 4 nuts.

      Torque:
      Bolt A
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Bolt B
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  53. INSTALL NO. 2 FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY


    1. B004B8U

      Install the No. 2 front bumper reinforcement sub-assembly with the 6 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  54. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

  55. INSTALL FRONT BUMPER COVER

    Click here

  56. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY


    1. B004CNE

      Connect the No. 2 fuel tube sub-assembly and clamp.

      Click here

  57. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. B004BER

      Connect the fuel tube sub-assembly and clamp.

      Click here

  58. CONNECT NO. 3 ENGINE WIRE


    1. B0049T3

      Connect the No. 3 engine wire with the bolt and 2 clamps.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  59. CONNECT NO. 3 ENGINE ROOM WIRE

    B004AT4

    1. Connect the connector of the air conditioning wire.

    2. Connect the No. 3 engine room wire with the 2 connectors.

    3. Install the No. 3 engine room wire with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  60. CONNECT ENGINE WIRE


    1. B004C53

      Connect the 3 connectors of the engine wire to the relay block.

    2. B004AA6

      Connect the clamp and 2 claws.

  61. INSTALL ECM

    Click here

  62. INSTALL NO. 2 RELAY BLOCK COVER


    1. B004AXQ

      Attach the 4 claws to install the No. 2 relay block cover.

  63. CONNECT SUCTION HOSE SUB-ASSEMBLY A

    Click here

  64. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  65. CONNECT TRANSMISSION OIL COOLER HOSE

    Click here

  66. CONNECT NO. 2 OIL COOLER OUTLET HOSE

    Click here

  67. CONNECT WATER HOSE SUB-ASSEMBLY

    Click here

  68. CONNECT INLET HEATER WATER HOSE


    1. B004AYPN01

      Connect the inlet heater water hose to the No. 3 water by-pass hose assembly, and slide the clamp to secure the hose.

  69. CONNECT OUTLET HEATER WATER HOSE


    1. B004CJWN01

      Connect the outlet heater water hose to the No. 2 water by-pas pipe assembly, and slide the clamp to secure the hose.

  70. CONNECT NO. 3 RADIATOR HOSE

    Click here

  71. CONNECT NO. 1 RADIATOR HOSE

    Click here

  72. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. B004AY2

      Connect the No. 1 fuel vapor feed hose to the purge VSV.

  73. CONNECT GENERATOR CABLE

    Click here

  74. CONNECT MOTOR CABLE

    Click here

  75. INSTALL INVERTER TERMINAL COVER

    Click here

  76. INSTALL AIR CLEANER WITH AIR CLEANER HOSE

    Click here

  77. CONNECT NO. 2 PCV HOSE

    Click here

  78. INSTALL NO. 1 AIR CLEANER INLET

    Click here

  79. INSTALL RADIATOR SUPPORT TO CROSS MEMBER BRACE SUB-ASSEMBLY LH

    Click here

  80. INSTALL RADIATOR SUPPORT TO CROSS MEMBER BRACE SUB-ASSEMBLY RH

    Click here

  81. ADD ENGINE OIL

    Click here

  82. ADD HYBRID TRANSMISSION FLUID

    Click here

  83. INSTALL SERVICE PLUG GRIP

    Click here

  84. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

  85. PERFORM INITIALIZATION

    Click here

  86. PARKING LOCK FORCED RELEASE

    Click here

  87. INSPECT SHIFT LEVER POSITION

    Click here

  88. ADD ENGINE COOLANT

    Click here

  89. ADD COOLANT (for Inverter)

    Click here

  90. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


  91. INSPECT FOR ENGINE COOLANT LEAK

    Click here

  92. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  93. INSPECT FOR OIL LEAK

    Click here

  94. INSPECT FOR FUEL LEAK

    Click here

  95. INSPECT FOR EXHAUST GAS LEAK

    Click here

  96. INSPECT FOR REFRIGERANT LEAK


  97. INSTALL FRONT WHEEL

    Click here

  98. STABILIZE SUSPENSION

    Click here

  99. FULLY TIGHTEN LOWER NO. 2 SUSPENSION ARM ASSEMBLY LH

    Click here

  100. FULLY TIGHTEN LOWER NO. 2 SUSPENSION ARM ASSEMBLY RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  101. FULLY TIGHTEN FRONT LOWER SUSPENSION ARM ASSEMBLY LH

    Click here

  102. FULLY TIGHTEN FRONT LOWER SUSPENSION ARM ASSEMBLY RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  103. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  104. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  105. VARIABLE GEAR RATIO STEERING SYSTEM CALIBRATION (w/ VGRS)

    Click here

  106. INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  107. INSPECT IGNITION TIMING

    Click here

  108. INSPECT ENGINE IDLE SPEED

    Click here

  109. INSPECT CO/HC

    Click here

  110. INSPECT ENGINE OIL LEVEL

    Click here

  111. INSTALL STRUT BAR BRACKET SUPPORT SUB-ASSEMBLY


    1. B004BA0

      Install the strut bar bracket support sub-assembly with 4 new bolts.

      Torque:
      7.9 N*m  { 81 kgf*cm, 70 in.*lbf }

  112. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY


    1. B004A9J

      Install the No. 2 engine under cover assembly with the clip and 10 new bolts.

      Torque:
      7.9 N*m  { 81 kgf*cm, 70 in.*lbf }

  113. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY


    1. B004CUM

      Install the No. 1 engine under cover assembly with the 15 screws and 3 clips.

  114. INSTALL RADIATOR SUPPORT TO FRAME SEAL RH

    Click here

  115. INSTALL LOWER RADIATOR AIR DEFLECTOR

    Click here

  116. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. B004BSFC01
      *a Tip (Round Portion)

      Attach the 3 clips in the order shown in the illustration to install the V-bank cover sub-assembly.

      Note


      • Securely attach the clips.

      • If the clips are forcibly attached or struck with an object, they may be damaged.

      • Do not apply any oil to the tips (round portions).

  117. INSTALL NO. 2 DECK BOARD