ENGINE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. Gently place the engine assembly onto wooden blocks or equivalent.

      Note

      This step should be done while hanging the engine assembly using the engine hangers and a chain block.

    2. Install the flywheel sub-assembly Click here.

  2. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY


    1. Gently place the engine assembly onto wooden blocks or equivalent.

      Note

      This step should be done while hanging the engine assembly using the engine hangers and a chain block.

    2. Install the transmission input damper assembly Click here.

  3. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. Install the hybrid vehicle transaxle assembly Click here.

      Note

      Be careful not to apply excess force to the transmission input damper assembly when removing or installing the hybrid vehicle transaxle assembly. If excess force is applied, the transmission input damper assembly may be damaged, or its splines may become misaligned.

  4. INSTALL ENGINE WIRE

  5. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  6. INSTALL STARTER HOLE INSULATOR

    Click here

  7. INSTALL RADIATOR PIPE


    1. Install the No. 3 radiator hose and slide the clip to secure it.

    2. Install the radiator pipe with the 2 bolts.

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

  8. 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. B001MDNE02

      Position the engine mounting insulator sub-assembly RH as shown in the illustration.

    2. Temporarily install bolt (A) to the engine mounting insulator sub-assembly RH.

    3. Tighten the 3 bolts to the engine mounting insulator sub-assembly RH in the order bolt (B), bolt (C) and bolt (A).

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    4. Install the 2 cooler brackets with the 2 bolts.

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

  9. INSTALL RADIATOR RESERVOIR TANK ASSEMBLY

    Tech Tips

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


    1. Install the radiator reservoir tank assembly with the 2 bolts.

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

  10. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B001MVEE02

      Temporarily install bolt (A) to the engine mounting insulator LH.

    2. Tighten the 4 bolts to the engine mounting insulator LH in the order bolt (C), bolt (B), bolt (D) and bolt (A).

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  11. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Install the rear engine mounting insulator to the rear engine mounting bracket with the bolt.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  12. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. B001MYD

      Temporarily install the front engine mounting insulator with the bolt and nut.

  13. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine assembly with transaxle on the engine lifter.

      Note

      Place height adjustment attachments and plate lift attachments under the engine assembly with transaxle.

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

    3. Set the engine assembly with transaxle on an engine lifter.

    4. Operate the engine lifter to lift the engine assembly with transaxle to the position where the engine mounting insulator sub-assembly RH and engine mounting insulator LH can be installed.

      CAUTION:

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

      Note


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

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

    5. Install the front crossmember sub-assembly with the 4 bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }
    6. B001KU8

      Install the front engine mounting insulator to the front crossmember sub-assembly with the 2 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    7. Install the engine mounting insulator LH with the bolt and nut.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }
    8. B001MCIE01

      Install the engine mounting insulator sub-assembly RH with the bolt and 2 nuts.

      Torque:
      Nut A
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      Nut B
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
      Bolt
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
    9. B001LYQ

      Tighten the front engine mounting insulator with the bolt and nut.

      Torque:
      145 N*m  { 1479 kgf*cm, 107 ft.*lbf }

      Note

      When tightening the bolt, keep the nut from rotating.

  14. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  15. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  16. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  17. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  18. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Click here

  19. INSTALL FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT

    Click here

  20. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  21. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH

    Tech Tips

    Perform the same procedure as for the LH side.

  22. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  23. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  24. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

    Click here

  25. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  26. INSTALL FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  27. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  28. CONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  29. CONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  30. INSTALL FRONT SPEED SENSOR LH

    Click here

  31. INSTALL FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  32. INSTALL FRONT AXLE SHAFT NUT LH

    Click here

  33. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  34. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  35. INSTALL FRONT CENTER FLOOR BRACE

    Click here

  36. INSTALL FRONT NO. 3 ENGINE UNDER COVER

    Click here

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

    Click here

  38. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  39. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  40. INSTALL WIRE HARNESS


    1. Connect the engine wire with the 2 clamps.

    2. Install the earth wire with the bolt.

    3. Connect the engine wire with the 2 clamps.

    4. B001MNI

      Connect the engine wire, 2 clamps and 2 connectors to the engine room junction block.

    5. B001MAU

      Connect the ECM connector and lower the lever.

    6. Connect the 2 clamps.

  41. INSTALL ELECTRIC INVERTER COMPRESSOR

    Click here

  42. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube connector and fuel pipe.

      CAUTION:

      Align the fuel tube connector with the fuel pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If the connection is tight, apply a small amount of engine oil to the tip of the fuel pipe. After connecting, pull the fuel pipe and fuel tube connector to make sure that they are securely connected.

    2. Engage the claw and install the No. 1 fuel pipe clamp.

  43. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. B001N57E01
      Text in Illustration
      *a FR
      *b RH

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

  44. CONNECT HEATER HOSE


    1. Connect the heater hose and slide the clip to secure it.

  45. CONNECT INLET HEATER WATER HOSE


    1. Connect the inlet heater water hose and slide the clip to secure it.

  46. CONNECT OUTLET HEATER WATER HOSE


    1. Connect the outlet heater water hose and slide the clip to secure it.

  47. CONNECT NO. 5 INVERTER COOLING HOSE


    1. Connect the No. 5 inverter cooling hose to the hybrid transaxle assembly and slide the clip to secure it.

  48. CONNECT NO. 3 INVERTER COOLING HOSE


    1. Connect the No. 3 inverter cooling hose to the hybrid transaxle assembly and slide the clip to secure it.

  49. CONNECT NO. 4 WATER BY-PASS HOSE


    1. Connect the No. 4 water by-pass hose to the radiator pipe and slide the clip to secure it.

  50. CONNECT NO. 2 RADIATOR HOSE


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

  51. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the radiator pipe and slide the clip to secure it.

  52. INSTALL INVERTER TRAY BRACKET


    1. B001KY5E02

      Position the inverter tray bracket as shown in the illustration.

    2. Temporarily install bolt (B) to the inverter tray bracket.

    3. Tighten the 5 bolts to the inverter tray bracket in the order bolt (A), bolt (C), bolt (D), bolt (E) and bolt (B).

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    4. Connect the 2 clamps to the inverter tray bracket.

  53. INSTALL INVERTER RESERVE TANK ASSEMBLY


    1. B001M9ZE02

      Temporarily install bolt (A) to the inverter reserve tank assembly.

    2. Tighten the 2 bolts to the inverter reserve tank assembly in the order bolt (B) and bolt (A).

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

  54. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    Click here

  55. CONNECT WATER HOSE

    Click here

  56. CONNECT NO. 2 ENGINE ROOM WIRE

    Click here

  57. REMOVE INVERTER COVER

    Click here

  58. CONNECT NO. 2 ENGINE WIRE

    Click here

  59. CONNECT MOTOR CABLE

    Click here

  60. CONNECT GENERATOR CABLE

    Click here

  61. CONNECT FRAME WIRE

    Click here

  62. CHECK HIGH VOLTAGE CABLE CONNECTION

    Click here

  63. INSTALL INVERTER COVER

    Click here

  64. CONNECT ENGINE ROOM MAIN WIRE

    Click here

  65. INSTALL NO. 1 INVERTER BRACKET

    Click here

  66. INSTALL AIR CLEANER HOSE ASSEMBLY

    Click here

  67. INSTALL AIR CLEANER CASE


    1. Install the air cleaner case with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the wire harness clamp to the air cleaner case.

    3. Connect the No. 4 water by-pass hose to the air cleaner case.

  68. INSTALL INLET AIR CLEANER


    1. Install the inlet air cleaner with the 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the wire harness clamp to the inlet air cleaner.

  69. INSTALL WATER HOSE HOSE CLAMP


    1. Install the water hose hose clamp with the 2 clips.

    2. Connect the water by-pass hose to the water hose hose clamp.

  70. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Install the air cleaner filter element sub-assembly.

    2. Install the air cleaner cap sub-assembly with the 2 clamps.

    3. Connect the air cleaner hose assembly and tighten the hose clamp.

    4. Connect the water by-pass hose to the air cleaner cap sub-assembly.

    5. Connect the air flow meter connector.

  71. INSTALL SERVICE PLUG GRIP

    Click here

  72. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL


    1. Connect the cable to the negative (-) auxiliary battery terminal with the nut.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      Note

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

  73. INSTALL REAR FLOOR BOARD UPPER NO. 3 PLATE

    Click here

  74. INSTALL DECK FLOOR BOX RH

    Click here

  75. INSTALL REAR NO. 3 FLOOR BOARD

    Click here

  76. INSTALL REAR DECK FLOOR BOX

    Click here

  77. INSTALL REAR NO. 2 FLOOR BOARD

    Click here

  78. ADD HYBRID TRANSAXLE FLUID

    Click here

  79. INSPECT HYBRID TRANSAXLE FLUID

    Click here

  80. ADD COOLANT (for Engine)

    Click here

  81. ADD COOLANT (for Inverter)

    Click here

  82. ADD ENGINE OIL

    Click here

  83. INSPECT ENGINE OIL LEVEL

    Click here

  84. INSPECT FOR FUEL LEAK

    Click here

  85. INSPECT FOR COOLANT LEAK (for Engine)

    Click here

  86. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  87. INSPECT FOR OIL LEAK

  88. INSPECT FOR EXHAUST GAS LEAK

  89. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 engine under cover with the 2 bolts and 13 clips.

  90. INSTALL FRONT LOWER BUMPER ABSORBER


    1. Install the front lower bumper absorber with the 8 bolts and 4 screws.

  91. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the 5 clips.

  92. INSTALL REAR ENGINE UNDER COVER RH


    1. Install the rear engine under cover RH with the 5 clips.

  93. INSTALL FRONT WHEEL

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  94. INSPECT IGNITION TIMING

    Click here

  95. INSPECT ENGINE IDLE SPEED

    Click here

  96. INSPECT CO/HC

    Click here

  97. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  98. INSTALL NO. 2 CYLINDER HEAD COVER


    1. B001LKQ

      Engage the 3 clips to install the No. 2 cylinder head cover.

      Note


      • Be sure to engage the clips securely.

      • Do not apply excessive force or hit the No. 2 cylinder head cover to engage the clips. This may cause the No. 2 cylinder head cover to break.

  99. INSTALL INVERTER COVER ASSEMBLY LH (w/ Cover)

    Click here

  100. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

  101. CHECK SPEED SENSOR SIGNAL

    Click here