ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing a 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. A00229HC01
      *a Claw

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

      Torque:
      11.5 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. Remove the engine assembly from the engine stand.

  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 INLET HEATER WATER HOSE B


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

  8. INSTALL OUTLET HEATER WATER HOSE A


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

    2. A00212VC01
      *1 Paint Mark
      *2 Protrusion
      *a Upper
      *b Front

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

      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 VALVE (PURGE VSV)

    Click here

  12. INSTALL INJECTOR DRIVER

    Click here

  13. INSTALL THROTTLE BODY GASKET

    Click here

  14. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  15. INSTALL FAN AND GENERATOR V BELT

    Click here

  16. INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

  17. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY

    Click here

  18. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  19. INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here

  20. INSTALL OIL COOLER WITHOUT HOSE TUBE SUB-ASSEMBLY

    Click here

  21. CONNECT WIRE HARNESS

    Click here

  22. INSTALL MOTOR HEAT INSULATOR

    Click here

  23. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)

    Click here

  24. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  25. 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 }

  26. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  27. 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 }

  28. INSTALL ENGINE OIL LEVEL DIPSTICK


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

  29. 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 steering sliding with shaft yoke sub-assembly.

    4. A00219SC02
      B003XUN Bolt
      B003YHT Nut

      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 }

    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:
      34.7 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 }

  30. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  31. CONNECT SUCTION HOSE

    Click here

  32. 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 }

  33. INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  34. CONNECT WIRE HARNESS


    1. A0022OV

      Connect the 2 wire harness clamps and 3 wire harness connectors to the power steering link assembly.

      Tech Tips

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

  35. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

  36. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  37. 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:
      180 N*m  { 1835 kgf*cm, 133 ft.*lbf }

      Note


      • Insert the bolt from the rear of the vehicle.

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

  38. CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  39. INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

    Click here

  40. INSTALL ENGINE UNDER BRACE SUB-ASSEMBLY


    1. Install the engine under brace sub-assembly with the 4 bolts.

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

  41. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 2 bolts.

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

  42. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  43. CONNECT AIR CONDITIONING HARNESS


    1. A0020WXC01
      *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.

  44. CONNECT ENGINE WIRE


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

    2. A0021VCC01
      *a Lock

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

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

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

  45. CONNECT GENERATOR CABLE

    Click here

  46. CONNECT MOTOR CABLE

    Click here

  47. INSTALL INVERTER TERMINAL COVER

    Click here

  48. INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY

    Click here

  49. INSTALL ECM

    Click here

  50. INSTALL NO. 1 INVERTER RESERVE TANK BRACKET


    1. A00231IC01
      *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. for LHD:


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

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

    4. Install 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 NO. 1 WATER HOSE CLAMP BRACKET


    1. A002271C01
      *a Claw

      Install the No. 1 water hose clamp bracket with the bolt and nut.

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

      Tech Tips

      Insert the claw of the water hose clamp bracket into the hole of the body as shown in the illustration.

  52. INSTALL INVERTER RESERVE TANK ASSEMBLY (for LHD)


    1. A00231CC01
      *1 No. 1 Inverter Cooling Hose
      *2 Inlet Hybrid Water Pump Hose
      *a Front
      *b Left
      *c Upper
      *d Rear

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

      Torque:
      12.5 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 it.

      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. Engage the clamp to connect the No. 1 inverter cooling hose to the No. 1 water hose clamp bracket.

    4. Connect the inlet hybrid water pump hose to the inverter water pump assembly and slide the clip to secure it.

      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.

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

    6. Engage the 2 wire harness clamps.

    7. Connect the 2 connectors.

  53. INSTALL INVERTER RESERVE TANK ASSEMBLY (for RHD)


    1. A00218EC01
      *1 Inlet Hybrid Water Pump Hose
      *2 No. 3 Inverter Cooling Hose
      *a Front
      *b Left

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

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

    2. Connect the inlet hybrid water pump hose to the inverter water pump assembly and slide the clip to secure it.

      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. Engage the clamp to connect the inlet hybrid water pump hose to the No. 1 inverter reserve tank bracket and slide the clip to secure it.

    4. Engage the 2 clamps to connect the No. 3 inverter cooling hose to the No. 1 inverter reserve tank bracket and HV water pump bracket sub-assembly.

    5. A00239BC01
      *a Upper
      *b Front

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

      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 OUTLET NO. 1 HV WATER PUMP PIPE


    1. A0022VXC01
      *1 Outlet No. 1 HV Water Pump Pipe
      *2 Outlet No. 1 Hybrid Water Pump Hose
      *3

      for LHD: No. 2 Inverter Cooling Hose

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

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

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

    2. Connect the outlet No. 1 hybrid water pump hose to the inverter water pump assembly and slide the clip to secure it.

      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 LHD:


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

        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.

    4. for RHD:


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

        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.

  55. CONNECT INLET NO. 2 OIL COOLER HOSE


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

  56. CONNECT OUTLET NO. 2 OIL COOLER HOSE


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

  57. INSTALL FRONT UPPER NO. 2 SUSPENSION MEMBER


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

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

  58. CONNECT INLET HEATER WATER HOSE A

    Click here

  59. CONNECT OUTLET HEATER WATER HOSE A

    Click here

  60. CONNECT NO. 4 RADIATOR HOSE

    Click here

  61. INSTALL RADIATOR HOSE SUB-ASSEMBLY

    Click here

  62. 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.

  63. CONNECT NO. 2 FUEL VAPOR FEED HOSE


    1. Connect the No. 2 fuel vapor feed hose to the No. 1 vacuum switching valve assembly and slide the clip to secure it.

  64. INSTALL HEATER WATER PUMP ASSEMBLY

    Click here

  65. INSTALL AIR CLEANER HOSE ASSEMBLY

    Click here

  66. INSTALL AIR CLEANER ASSEMBLY WITH NO. 2 AIR CLEANER HOSE


    1. A0021Z5C01
      *1 Air Cleaner Support
      *a Groove
      *b Matchmark
      *c Pin

      Connect the air cleaner assembly with No. 2 air cleaner hose to the air cleaner hose assembly.

      Tech Tips

      Make sure the direction of the installation is as shown in the illustration.

    2. Insert the pin of the air cleaner assembly with No. 2 air cleaner hose into the hole of the air cleaner support as shown in the illustration.

    3. Install the 2 bolts.

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

    4. Tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    5. Connect the 2 wire harness clamps to the air cleaner assembly with No. 2 air cleaner hose.

    6. Connect the mass air flow meter sub-assembly connector.

  67. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the air cleaner case sub-assembly is necessary.


    1. A00231LC01
      *1 Air Cleaner Support
      *a Pin

      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.

  68. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the air cleaner filter element sub-assembly is necessary.


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

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

    Tech Tips

    Perform this procedure only when replacement of the air cleaner filter element sub-assembly or air cleaner case sub-assembly is necessary.

    Click here

  70. INSTALL INLET NO. 1 AIR CLEANER


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

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

  71. INSTALL SERVICE PLUG GRIP

    Click here

  72. ADD ENGINE OIL

    Click here

  73. ADD COOLANT (for Inverter)

    Click here

  74. ADD ENGINE COOLANT (for Engine)

    Click here

  75. INSPECT SHIFT LEVER POSITION

    Click here

  76. ADJUST SHIFT LEVER POSITION

    Click here

  77. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  78. INSPECT FOR COOLANT LEAK (for Engine)

    Click here

  79. INSPECT FOR OIL LEAK

  80. INSPECT FOR FUEL LEAK

    Click here

  81. INSPECT FOR EXHAUST GAS LEAK

  82. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  83. WARM UP COMPRESSOR

    Click here

  84. INSPECT FOR REFRIGERANT LEAK

    Click here

  85. INSTALL FRONT WHEELS

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

  86. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  87. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  88. PERFORM INITIALIZATION

    Click here

  89. INSPECT IGNITION TIMING

    Click here

  90. INSPECT ENGINE IDLE SPEED

    Click here

  91. INSPECT CO/HC

    Click here

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

    Click here

  93. INSPECT COOLANT LEVEL IN RESERVE TANK (for Inverter)

    Click here

  94. CHECK ENGINE OIL LEVEL

    Click here

  95. INSTALL NO. 2 ENGINE UNDER COVER (w/ No. 2 Engine Under Cover)


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

  96. INSTALL FRONT SUSPENSION MEMBER BRACE


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

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

  97. INSTALL REAR ENGINE UNDER COVER LH


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

  98. INSTALL REAR ENGINE UNDER COVER RH

    Tech Tips

    Use the same procedure described for the LH side.

  99. INSTALL ENGINE UNDER COVER


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

  100. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. A002382C01
      *a Tip (Round Portion)

      Engage 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 engaged or struck with an object, they may be damaged.

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

  101. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

  102. CHECK FOR SPEED SENSOR SIGNAL

    Click here