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.

Tech Tips

Perform "Inspection After Repair" after replacing the engine assembly, cylinder head sub-assembly, camshaft, No. 2 camshaft, camshaft timing gear assembly, camshaft timing exhaust gear assembly, piston or piston ring set.


PROCEDURE


  1. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.


    1. B002BQ7E02
      Text in Illustration
      *a Claw

      Install the rear No. 1 engine mounting insulator to the hybrid vehicle transmission assembly with the 4 bolts.

      Torque:
      12 N*m  { 117 kgf*cm, 8 ft.*lbf }

      Tech Tips

      Make sure that the claw is facing towards the front of the vehicle.

  2. INSTALL REAR ENGINE MOUNTING MEMBER

    Tech Tips

    Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.


    1. Install the rear engine mounting member to the rear No. 1 engine mounting insulator with the 4 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  3. INSTALL FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Install the 2 front engine mounting insulators to the front suspension crossmember sub-assembly with the 2 nuts.

      Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

  4. INSTALL ENGINE HANGER

    Click here

  5. REMOVE ENGINE ASSEMBLY FROM 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.

  6. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. Install the front suspension crossmember sub-assembly to the engine assembly with the 2 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  7. INSTALL HEATER WATER HOSE INLET B


    1. Connect the heater water hose inlet B to the No. 3 water by-pass pipe and slide the clip to secure the hose.

  8. INSTALL HEATER WATER HOSE OUTLET A


    1. Install the water hose set to the heater water hose outlet A.

    2. B002BASE05
      Text in Illustration
      *a Paint Mark
      *b Protrusion
      *c Upper
      *d Front

      Align the paint mark on the outlet heater water hose with the protrusion of the No. 2 water by-pass pipe, connect the heater water outlet hose A to the No. 2 water by-pass pipe and slide the clip to secure the hose.

      Tech Tips

      Make sure that the clip is positioned as shown in the illustration.

  9. INSTALL INTAKE MANIFOLD

    Click here

  10. INSTALL NO. 2 EGR PIPE (w/ EGR System)

    Click here

  11. INSTALL PURGE VSV

    Click here

  12. INSTALL INJECTOR DRIVER

    Click here

  13. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  14. INSTALL FAN AND GENERATOR V BELT

    Click here

  15. INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

  16. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY

    Click here

  17. CONNECT ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  18. INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here

  19. INSTALL OIL COOLER WITHOUT HOSE TUBE SUB-ASSEMBLY

    Click here

  20. INSTALL WIRE HARNESS

    Click here

  21. INSTALL MOTOR HEAT INSULATOR

    Click here

  22. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  23. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  24. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 3 exhaust manifold heat insulator to the camshaft housing sub-assembly with the 2 nuts.

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

  25. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  26. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the engine oil level dipstick guide.

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

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

  27. INSTALL ENGINE OIL LEVEL DIPSTICK


    1. Install the engine oil level dipstick to the engine oil level dipstick guide.

  28. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION

    Tech Tips

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



    1. Set the engine assembly with transmission on an engine lifter.

      Note


      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transmission horizontally.

      • 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 or removed from an engine stand.

      • To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transmission.

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

    3. Operate the engine lifter and install the engine assembly with transmission to the vehicle.

      Note

      Make sure that the engine assembly with transmission is clear of all wiring, hoses and the steering sliding with shaft yoke sub-assembly.

    4. B002BZSE02

      Install the strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly with the 6 bolts and 2 nuts.

      Torque:
      Bolt A
      194 N*m  { 1978 kgf*cm, 143 ft.*lbf }
      Bolt B
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }
      Nut
      151 N*m  { 1540 kgf*cm, 111 ft.*lbf }
      Text in Illustration
      B002B6O Bolt
      B002BBR Nut

    5. Install the front No. 2 stabilizer bracket LH and front No. 2 stabilizer bracket RH with the 4 bolts.

      Torque:
      Bolt C
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

    6. Install the rear engine mounting member with the 4 bolts.

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

    7. Connect the No. 2 earth wire with the nut.

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

  29. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. Install the front lower suspension member protector to the front suspension crossmember sub-assembly with the 4 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  30. INSTALL FRONT NO. 2 UPPER SUSPENSION MEMBER


    1. Install the 2 front No. 2 upper suspension members with the 6 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  31. INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  32. CONNECT POWER STEERING LINK WIRE HARNESS


    1. B002BTOE02

      Connect the wire harness connector (C) to the power steering link assembly and securely lock the connector.

      Tech Tips

      For the connector with lock lever, fully insert the connector and push down the lock lever to engage the lock.

    2. Connect the 2 wire harness connectors (A and B) to the power steering link assembly.

    3. Connect the 2 wire harness clamps to the bracket.

  33. CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

  34. CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  35. CONNECT FRONT SHOCK ABSORBER ASSEMBLY LH


    1. Connect the lower part of the front shock absorber assembly LH to the front lower suspension arm assembly with the bolt and nut.

      Torque:
      108 N*m  { 1101 kgf*cm, 80 ft.*lbf }

      Note


      • Insert the bolt from the rear of the vehicle.

      • When tightening the bolt, keep the nut from rotating.

  36. CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  37. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

    Click here

  38. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  39. FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING ASSEMBLY

    Click here

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

    Click here

  41. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR

    Click here

  42. INSTALL NO. 1 FUEL TANK PROTECTOR

    Click here

  43. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY


    1. Install the front center floor brace sub-assembly with the 4 bolts.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }

  44. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  45. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  46. CONNECT HEATED OXYGEN SENSOR


    1. Connect the clamp.

    2. Connect the heated oxygen sensor connector.

  47. INSTALL FRONT CENTER FLOOR BRACE

    Click here

  48. INSTALL NO. 2 REAR FLOOR BOARD SUB-ASSEMBLY

    Click here

  49. INSTALL NO. 1 REAR FLOOR BOARD SUB-ASSEMBLY

    Click here

  50. INSTALL NO. 1 INVERTER RESERVE TANK BRACKET


    1. B002BMVE02
      Text in Illustration
      *a Claw

      Install the No. 1 inverter reserve tank bracket with the 2 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      Tech Tips

      Insert the claw of the No. 1 inverter reserve tank bracket into the hole of the body as shown in the illustration.

    2. Attach the 2 wire harness clamps to the No. 1 inverter reserve tank bracket.

    3. Connect the No. 3 engine wire to the No. 1 inverter reserve tank bracket with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  51. INSTALL INVERTER RESERVE TANK ASSEMBLY (for LHD)


    1. B002BHTE02
      Text in Illustration
      *1 No. 1 Inverter Cooling Hose
      *2 Hybrid Water Pump Inlet Hose
      *3 No. 3 Inverter Cooling Hose
      *a Upper
      *b Rear

      Install the inverter reserve tank assembly to the No. 1 inverter reserve tank bracket with the 2 bolts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

    2. Connect the No. 1 inverter cooling hose to the inverter reserve tank assembly and slide the clip to secure the hose.

      Note

      To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipe and disconnected hose until installation.

      Tech Tips

      Make sure that the clip is positioned as shown in the illustration.

    3. Attach the wire harness clamp from the inverter reserve tank assembly.

    4. Attach the clamp to connect the No. 3 inverter cooling hose to the No. 1 inverter reserve tank bracket.

    5. Attach the clamp to connect the hybrid water pump inlet hose to the No. 1 inverter reserve tank bracket.

  52. INSTALL INVERTER RESERVE TANK ASSEMBLY (for RHD)


    1. Install the inverter reserve tank assembly to the No. 1 inverter reserve tank bracket with the 2 bolts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

    2. Attach the clamp to connect the hybrid water pump inlet hose to the No. 1 inverter reserve tank bracket.

    3. Attach the clamp to connect the No. 3 inverter cooling hose to the No. 1 inverter reserve tank bracket.

    4. B002BIDE02
      Text in Illustration
      *a Upper
      *b Front

      Connect the inverter drain hose to the HV radiator outlet pipe and slide the clip to secure the hose.

      Note

      To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipe and disconnected hose until installation.

      Tech Tips

      Make sure that the clip is positioned as shown in the illustration.

  53. INSTALL NO. 1 HV WATER PUMP OUTLET PIPE


    1. B002BHEE02
      Text in Illustration
      *1 No. 1 HV Water Pump Outlet Pipe
      *2

      for LHD: No. 2 Inverter Cooling Hose

      for RHD: No. 5 Inverter Cooling Hose
      *a Right
      *b Front

      Install the No. 1 HV water pump outlet pipe to the stiffening crankcase assembly with the 2 bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    2. for LHD:


      1. Connect the No. 2 inverter cooling hose to the No. 1 HV water pump outlet pipe and slide the clip to secure the hose.

        Note

        To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipe and disconnected hose until installation.

        Tech Tips

        Make sure that the clip is positioned as shown in the illustration.

    3. for RHD:


      1. Connect the No. 5 inverter cooling hose to the No. 1 HV water pump outlet pipe and slide the clip to secure the hose.

        Note

        To prevent foreign matter from entering the cooling system, do not remove the pieces of cloth or plastic bags from the pipe and disconnected hose until installation.

        Tech Tips

        Make sure that the clip is positioned as shown in the illustration.

  54. INSTALL HV WATER PUMP BRACKET SUB-ASSEMBLY

    Click here

  55. CONNECT ENGINE WIRE


    1. for LHD:


      1. Attach the wire harness clamp.

      2. Connect the 2 connectors.

    2. Attach the 3 claws to connect the No. 2 connector holder to the engine room relay block and junction block assembly.

    3. B002B5AE02
      Text in Illustration
      *a Lock

      Connect the connector (A) to the No. 2 connector holder.

    4. Connect the connector (B) to the No. 2 connector holder and push down the lock lever to lock it.

    5. Install the No. 1 engine room relay block cover to the engine room relay block and junction block assembly.

  56. INSTALL ECM

    Click here

  57. INSTALL AIR CONDITIONING HARNESS


    1. B002BBBE01
      Text in Illustration
      *a Green-colored Lock

      Connect the connector and slide the green-colored lock as shown in the illustration to engage it securely.

      CAUTION:

      Make sure to wear insulating gloves.

      Note

      Make sure that the connector is connected securely.

    2. Connect the 2 wire harness clamps.

  58. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  59. CONNECT SUCTION HOSE

    Click here

  60. CONNECT NO. 2 OIL COOLER INLET HOSE


    1. Connect the No. 2 oil cooler inlet hose to the oil cooler tube sub-assembly and slide the clip to secure the hose.

  61. CONNECT NO. 2 OIL COOLER OUTLET HOSE


    1. Connect the No. 2 oil cooler outlet hose to the oil cooler tube sub-assembly and slide the clip to secure the hose.

  62. INSTALL HEATER WATER PUMP ASSEMBLY

    Click here

  63. CONNECT HEATER WATER HOSE INLET A

    Click here

  64. CONNECT HEATER WATER HOSE OUTLET A

    Click here

  65. CONNECT NO. 2 RADIATOR HOSE SUB-ASSEMBLY

    Click here

  66. INSTALL RADIATOR HOSE SUB-ASSEMBLY

    Click here

  67. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube sub-assembly to the fuel delivery pipe Click here.

    2. Connect the fuel tube sub-assembly to the fuel pump with seal sub-assembly Click here.

    3. Connect the No. 1 fuel tube clamp to the wire harness clamp bracket.

  68. CONNECT NO. 2 FUEL VAPOR FEED HOSE


    1. Connect the No. 2 fuel vapor feed hose to the purge VSV and slide the clip to secure the hose.

  69. CONNECT MOTOR CABLE

    Click here

  70. CONNECT GENERATOR CABLE

    Click here

  71. INSTALL ENGINE MOTOR CABLE CLAMP BRACKET (for LHD)


    1. Install the engine motor cable clamp bracket with the bolt.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    2. Attach the generator cable and motor cable to the engine motor cable clamp bracket.

  72. INSTALL INVERTER TERMINAL COVER

    Click here

  73. INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY

    Click here

  74. INSTALL AIR CLEANER HOSE ASSEMBLY

    Click here

  75. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. B002BGJE02
      Text in Illustration
      *a Pin
      *b Air Cleaner Support

      Insert the pin of the air cleaner case sub-assembly into the hole of the air cleaner support as shown in the illustration.

    2. Install the 2 bolts.

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

    3. Connect the wire harness clamp to the air cleaner case sub-assembly.

  76. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

  77. INSTALL AIR CLEANER CAP WITH NO. 2 AIR CLEANER HOSE

    Click here

  78. INSTALL NO. 1 AIR CLEANER INLET


    1. Install the No. 1 air cleaner inlet with the bolt.

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

  79. INSTALL SERVICE PLUG GRIP

    Click here

  80. INSTALL LOWER HYBRID VEHICLE BATTERY COVER PANEL

    Click here

  81. INSTALL NO. 1 SEAT ARMREST CAP

    Click here

  82. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  83. INSTALL LUGGAGE COMPARTMENT TRIM COVER LH

    Click here

  84. INSTALL LUGGAGE COMPARTMENT FLOOR MAT

    Click here

  85. ADD ENGINE OIL

    Click here

  86. ADD COOLANT (for Inverter)

    Click here

  87. ADD ENGINE COOLANT (for Engine)

    Click here

  88. ADJUST SHIFT LEVER POSITION

    Click here

  89. INSPECT SHIFT LEVER POSITION

    Click here

  90. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  91. INSPECT FOR COOLANT LEAK (for Engine)

    Click here

  92. INSPECT FOR OIL LEAK

    Click here

  93. INSPECT FOR FUEL LEAK

    Click here

  94. INSPECT FOR EXHAUST GAS LEAK

    Click here

  95. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  96. WARM UP COMPRESSOR

    Click here

  97. INSPECT FOR REFRIGERANT LEAK

    Click here

  98. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  99. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  100. INSPECT IGNITION TIMING

    Click here

  101. INSPECT ENGINE IDLE SPEED

    Click here

  102. INSPECT CO/HC

    Click here

  103. PERFORM INITIALIZATION

    Click here

  104. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR (for Engine)

    Click here

  105. INSPECT COOLANT LEVEL IN RESERVOIR TANK (for Inverter)

    Click here

  106. INSPECT ENGINE OIL LEVEL

    Click here

  107. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 4 screws and 2 grommets.

  108. INSTALL FRONT SUSPENSION MEMBER BRACE


    1. Install the front suspension member brace with the 4 bolts and clip.

      Torque:
      52 N*m  { 53 kgf*cm, 38 ft.*lbf }

  109. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the screw.

  110. INSTALL REAR ENGINE UNDER COVER RH

    Tech Tips

    Use the same procedure described for the LH side.

  111. INSTALL ENGINE UNDER COVER


    1. Install the engine under cover with the 13 screws and 3 clips.

  112. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. B002BJHE02
      Text in Illustration
      *a Tip (Round Portion)

      Attach the 3 clips in the order shown in the illustration to install the No. 1 engine cover sub-assembly.

      Note


      • Securely engage the clips.

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

  113. INSTALL COOL AIR INTAKE DUCT SEAL


    1. Install the cool air intake duct seal with the 7 clips.

  114. INSTALL ENGINE ROOM SIDE COVER


    1. Install the engine room side cover with the 4 clips.

  115. CHECK SPEED SENSOR SIGNAL WAVEFORM

    Click here