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 REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A000N6NE01
      Text in Illustration
      *1 Paint Mark
      B002B6O Rear of Vehicle

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

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

      Tech Tips

      Make sure that the paint mark faces toward the rear of the vehicle.

  2. INSTALL FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Install the front engine mounting insulator RH and LH with the 2 nuts.

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

  3. INSTALL ENGINE HANGER

    Click here

  4. 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.

  5. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


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

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

  6. INSTALL FAN AND GENERATOR V BELT

    Click here

  7. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  8. INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

  9. INSTALL TRANSMISSION INPUT DAMPER COVER ASSEMBLY

    Click here

  10. INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here

  11. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  12. INSTALL STARTER HOLE INSULATOR

    Click here

  13. INSTALL TRANSMISSION BREATHER HOSE SUB-ASSEMBLY

    Click here

  14. INSTALL WATER PIPE AND HOSE SUB-ASSEMBLY

    Click here

  15. INSTALL OIL COOLER HOSE TUBE SUB-ASSEMBLY

    Click here

  16. CONNECT WIRE HARNESS

    Click here

  17. CONNECT CONNECTOR

    Click here

  18. INSTALL REAR ENGINE MOUNTING MEMBER


    1. Install the engine rear mounting member to the hybrid vehicle transmission assembly with the 4 nuts.

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

  19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  20. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  21. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY LH


    1. Install the engine under cover sub-assembly LH.

  22. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY RH


    1. Install the engine under cover sub-assembly RH.

  23. 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 }

  24. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  25. INSTALL ENGINE AND TRANSMISSION ASSEMBLY


    1. 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. Remove the 4 bolts and 2 No. 1 engine hangers.

    3. Operate the engine lifter and install the engine to the vehicle.

      Note

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

    4. A000PLNE02

      Install the engine and transmission assembly with crossmember with the 6 bolts, 4 new bolts and 2 nuts.

      Torque:
      for bolt A
      194 N*m  { 1978 kgf*cm, 143 ft.*lbf }
      for bolt B
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }
      for bolt C
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
      for nut
      151 N*m  { 1540 kgf*cm, 111 ft.*lbf }
      Text in Illustration
      B002B6O Bolt
      B002BBR Nut

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

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

    6. Connect the wire harness with the nut.

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

  26. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. Install the front lower suspension member protector with the 4 bolts.

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

  27. 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 }

  28. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  29. CONNECT POWER STEERING LINK WIRE HARNESS


    1. A000S97E02

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

      Text in Illustration
      B002BBR Front

    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.

  30. CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

  31. CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

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

  32. 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.

  33. CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

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

  34. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (w/o VGRS)

    Click here

  35. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (w/ VGRS)

    Click here

  36. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  37. FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING ASSEMBLY

    Click here

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

    Click here

  39. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR

    Click here

  40. INSTALL NO. 1 FUEL TANK PROTECTOR

    Click here

  41. 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 }

  42. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY

    Click here

  43. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  44. CONNECT HEATED OXYGEN SENSOR (for Bank 2 Sensor 2)

    Click here

  45. CONNECT HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)

    Click here

  46. INSTALL FRONT CENTER FLOOR BRACE

    Click here

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

    Click here

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

    Click here

  49. CONNECT ENGINE WIRE


    1. Engine Room LH Side:


      1. Connect the No. 2 connector holder with the clamp and 3 claws.

      2. Connect the 3 connectors from the No. 2 connector holder.

      3. Install the No. 1 engine room relay block cover.

    2. Engine Room RH Side:


      1. Install the bolt, clamp and No. 3 engine wire.

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

  50. CONNECT INVERTER RESERVOIR TANK ASSEMBLY (for LHD)

    Click here

  51. CONNECT INVERTER RESERVOIR TANK ASSEMBLY (for RHD)

    Click here

  52. CONNECT MOTOR CABLE

    Click here

  53. CONNECT GENERATOR CABLE

    Click here

  54. INSTALL ECM

    Click here

  55. CONNECT SUCTION HOSE

    Click here

  56. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  57. INSTALL NO. 1 INVERTER COOLING PIPE (for LHD)


    1. Install the No. 1 inverter cooling pipe with the bolt.

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

    2. Connect the 2 hoses.

    3. Connect the 2 connectors and 2 wire harness clamps.

  58. CONNECT NO. 7 INVERTER COOLING HOSE (for RHD)


    1. Connect the No. 7 inverter cooling hose.

  59. CONNECT NO. 5 INVERTER COOLING HOSE (for LHD)


    1. Connect the No. 5 inverter cooling hose.

  60. CONNECT NO. 2 MOTOR COOLING HOSE (for RHD)


    1. Connect the No. 2 motor cooling hose.

  61. CONNECT NO. 2 OIL COOLER OUTLET HOSE

    Click here

  62. CONNECT NO. 2 OIL COOLER INLET HOSE

    Click here

  63. CONNECT AIR CONDITIONING HARNESS


    1. A000QRNE02
      Text in Illustration
      *1 White Tape
      *2 Air Conditioning Harness

      Connect the white tape part of the air conditioning harness to the clamp as shown in the illustration.

      Note

      Make sure that the air conditioning harness is securely connected.

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

    3. Connect the bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    4. A000R8HE01
      Text in Illustration
      *1 Green-colored Lock

      Connect the connector and lock the green-colored lock as shown in the illustration.

      CAUTION:

      Wear insulated gloves when performing the procedure.

  64. CONNECT OUTLET HEATER WATER HOSE


    1. Connect the outlet heater water hose.

    2. Install the water hose set.

  65. CONNECT INLET HEATER WATER HOSE


    1. Connect the inlet heater water hose.

    2. Install the water hose set.

  66. CONNECT NO. 2 RADIATOR HOSE

    Click here

  67. INSTALL NO. 1 RADIATOR HOSE

    Click here

  68. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube sub-assembly Click here.

  69. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY


    1. Connect the No. 2 fuel tube sub-assembly Click here.

  70. CONNECT NO. 3 FUEL TUBE SUB-ASSEMBLY


    1. Connect the No. 3 fuel tube sub-assembly Click here.

  71. CONNECT PURGE LINE HOSE


    1. Install the clamp and connect the purge line hose.

  72. INSTALL HEATER ACCESSORY ASSEMBLY

    Click here

  73. CONNECT WIRING HARNESS PROTECTOR

    Click here

  74. INSTALL OIL PUMP MOTOR CONTROLLER

    Click here

  75. CONNECT WIRE HARNESS

    Click here

  76. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A000OV0E04
      Text in Illustration
      *1 Pin
      *2 Grommet

      Insert the pin on the lower side of the air cleaner case into the grommet.

    2. Install the air cleaner case, 2 clamps and 2 bolts.

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

      Note

      During removal, do not lose the grommet on the underside of the air cleaner case.

  77. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  78. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  79. 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 }

  80. ADD ENGINE OIL

    Click here

  81. INSTALL CONNECTOR COVER ASSEMBLY

    Click here

  82. INSTALL INVERTER TERMINAL COVER

    Click here

  83. INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY

    Click here

  84. INSTALL INVERTER COVER

    Click here

  85. INSTALL SERVICE PLUG GRIP

    Click here

  86. INSTALL LOWER HYBRID VEHICLE BATTERY COVER PANEL

    Click here

  87. INSTALL NO. 1 SEAT ARMREST CAP

    Click here

  88. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

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

  89. INSTALL LUGGAGE COMPARTMENT TRIM COVER LH

    Click here

  90. INSTALL LUGGAGE COMPARTMENT FLOOR MAT

    Click here

  91. PERFORM INITIALIZATION

    Click here

  92. ADJUST SHIFT LEVER POSITION

    Click here

  93. INSPECT SHIFT LEVER POSITION

    Click here

  94. ADD ENGINE COOLANT

    Click here

  95. ADD COOLANT (for Inverter)

    Click here

  96. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for HFC-134a(R134a))

    Click here

  97. INSPECT FOR COOLANT LEAK

    Click here

  98. INSPECT COOLANT LEAK (for Inverter)

    Click here

  99. INSPECT FOR OIL LEAK

    Click here

  100. INSPECT FOR FUEL LEAK

    Click here

  101. INSPECT FOR EXHAUST GAS LEAK

    Click here

  102. CHECK FOR REFRIGERANT GAS LEAK (for HFC-134a(R134a))

    Click here

  103. INSTALL FRONT WHEEL

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

  104. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  105. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

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

    Click here

  107. ADJUST MILLIMETER WAVE RADAR SENSOR ASSEMBLY (w/ Dynamic Radar Cruise Control System)

    Click here

  108. INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  109. INSPECT IGNITION TIMING

    Click here

  110. INSPECT ENGINE IDLE SPEED

    Click here

  111. INSPECT CO/HC

    Click here

  112. INSPECT ENGINE COOLANT LEVEL

    Click here

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

    Click here

  114. INSPECT ENGINE OIL LEVEL

    Click here

  115. INSTALL NO. 2 ENGINE UNDER COVER


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

  116. INSTALL FRONT SUSPENSION MEMBER BRACE


    1. w/ Canister Pump Module:

      Install the front suspension member brace with the 6 bolts.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    2. w/o Canister Pump Module:

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

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  117. INSTALL REAR ENGINE UNDER COVER LH


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

  118. INSTALL REAR ENGINE UNDER COVER RH

    Tech Tips

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

  119. INSTALL ENGINE UNDER COVER


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

  120. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. A000OMDE02
      Text in Illustration
      *1 Tip (Round Portion)

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

      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).

  121. INSTALL COOL AIR INTAKE DUCT SEAL


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

  122. INSTALL ENGINE ROOM SIDE COVER


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