ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. Click here

   INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

   Tip:

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

   
   
   1. 

      *a

      Claw

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

      11.5 N*m

      117 kgf*cm

      8 ft.*lbf

      Tip:

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

2. Click here

   INSTALL REAR ENGINE MOUNTING MEMBER

   Tip:

   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.

      13 N*m

      133 kgf*cm

      10 ft.*lbf

3. Click here

   INSTALL FRONT ENGINE MOUNTING INSULATOR

   Tip:

   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.

      70 N*m

      714 kgf*cm

      52 ft.*lbf

4. Click here

   INSTALL ENGINE HANGER

   Click here

5. Click here

   REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

   
   

   1. Remove the engine assembly from the engine stand.

6. Click here

   INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

   
   

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

      35 N*m

      357 kgf*cm

      26 ft.*lbf

7. Click here

   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. Click here

   INSTALL OUTLET HEATER WATER HOSE A

   
   

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

   2. 

      *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.

      Tip:

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

9. Click here

   INSTALL INTAKE MANIFOLD

   Click here

10. Click here

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

    Click here

11. Click here

    INSTALL PURGE VALVE (PURGE VSV)

    Click here

12. Click here

    INSTALL INJECTOR DRIVER

    Click here

13. Click here

    INSTALL THROTTLE BODY GASKET

    Click here

14. Click here

    INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

15. Click here

    INSTALL FAN AND GENERATOR V BELT

    Click here

16. Click here

    INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

17. Click here

    INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY

    Click here

18. Click here

    INSTALL ENGINE WIRE

    
    

    1. Install the engine wire to the engine assembly.

19. Click here

    INSTALL HYBRID VEHICLE TRANSMISSION ASSEMBLY

    Click here

20. Click here

    INSTALL OIL COOLER WITHOUT HOSE TUBE SUB-ASSEMBLY

    Click here

21. Click here

    CONNECT WIRE HARNESS

    Click here

22. Click here

    INSTALL MOTOR HEAT INSULATOR

    Click here

23. Click here

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

    Click here

24. Click here

    INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

25. Click here

    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.

       10 N*m

       102 kgf*cm

       7 ft.*lbf

26. Click here

    INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

27. Click here

    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.

       10 N*m

       102 kgf*cm

       7 ft.*lbf

28. Click here

    INSTALL ENGINE OIL LEVEL DIPSTICK

    
    

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

29. Click here

    INSTALL ENGINE ASSEMBLY WITH TRANSMISSION

    Tip:

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

    
    

    • w/ EGR System:

      Click here

    • w/o EGR System:

      Click here

    
    

    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. 

       	Bolt
       	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.

       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.

       Bolt C
       49 N*m	500 kgf*cm	36 ft.*lbf

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

       34.7 N*m

       354 kgf*cm

       26 ft.*lbf

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

       5.4 N*m

       55 kgf*cm

       48 in.*lbf

30. Click here

    CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

31. Click here

    CONNECT SUCTION HOSE

    Click here

32. Click here

    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.

       5.5 N*m

       56 kgf*cm

       49 in.*lbf

33. Click here

    INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

34. Click here

    CONNECT WIRE HARNESS

    
    
    1. 

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

       Tip:

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

35. Click here

    INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

36. Click here

    INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

37. Click here

    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.

       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. Click here

    CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

39. Click here

    INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

    Click here

40. Click here

    INSTALL ENGINE UNDER BRACE SUB-ASSEMBLY

    
    

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

       7.4 N*m

       75 kgf*cm

       65 in.*lbf

41. Click here

    INSTALL MANIFOLD STAY

    
    

    1. Install the manifold stay with the 2 bolts.

       43 N*m

       438 kgf*cm

       32 ft.*lbf

42. Click here

    INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

43. Click here

    CONNECT AIR CONDITIONING HARNESS

    
    
    1. 

       *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. Click here

    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. 

       *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. Click here

    CONNECT GENERATOR CABLE

    Click here

46. Click here

    CONNECT MOTOR CABLE

    Click here

47. Click here

    INSTALL INVERTER TERMINAL COVER

    Click here

48. Click here

    INSTALL INVERTER MOTOR CABLE BRACKET ASSEMBLY

    Click here

49. Click here

    INSTALL ECM

    Click here

50. Click here

    INSTALL NO. 1 INVERTER RESERVE TANK BRACKET

    
    
    1. 

       *a

       Claw

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

       8.5 N*m

       87 kgf*cm

       75 in.*lbf

       Tip:

       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.

       8.5 N*m

       87 kgf*cm

       75 in.*lbf

51. Click here

    INSTALL NO. 1 WATER HOSE CLAMP BRACKET

    
    
    1. 

       *a

       Claw

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

       12.5 N*m

       127 kgf*cm

       9 ft.*lbf

       Tip:

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

52. Click here

    INSTALL INVERTER RESERVE TANK ASSEMBLY (for LHD)

    
    
    1. 

       *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.

       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.

       Tip:

       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.

       Tip:

       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. Click here

    INSTALL INVERTER RESERVE TANK ASSEMBLY (for RHD)

    
    
    1. 

       *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.

       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.

       Tip:

       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. 

       *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.

       Tip:

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

54. Click here

    INSTALL OUTLET NO. 1 HV WATER PUMP PIPE

    
    
    1. 

       *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.

       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.

       Tip:

       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.

          Tip:

          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.

          Tip:

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

55. Click here

    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. Click here

    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. Click here

    INSTALL FRONT UPPER NO. 2 SUSPENSION MEMBER

    
    

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

       20 N*m

       204 kgf*cm

       15 ft.*lbf

58. Click here

    CONNECT INLET HEATER WATER HOSE A

    Click here

59. Click here

    CONNECT OUTLET HEATER WATER HOSE A

    Click here

60. Click here

    CONNECT NO. 4 RADIATOR HOSE

    Click here

61. Click here

    INSTALL RADIATOR HOSE SUB-ASSEMBLY

    Click here

62. Click here

    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. Click here

    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. Click here

    INSTALL HEATER WATER PUMP ASSEMBLY

    Click here

65. Click here

    INSTALL AIR CLEANER HOSE ASSEMBLY

    Click here

66. Click here

    INSTALL AIR CLEANER ASSEMBLY WITH NO. 2 AIR CLEANER HOSE

    
    
    1. 

       *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.

       Tip:

       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.

       5.0 N*m

       51 kgf*cm

       44 in.*lbf

    4. Tighten the hose clamp.

       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. Click here

    INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Tip:

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

    
    
    1. 

       *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.

       5.0 N*m

       51 kgf*cm

       44 in.*lbf

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

68. Click here

    INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Tip:

    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. Click here

    INSTALL AIR CLEANER CAP WITH NO. 2 AIR CLEANER HOSE

    Tip:

    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. Click here

    INSTALL INLET NO. 1 AIR CLEANER

    
    

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

       5.0 N*m

       51 kgf*cm

       44 in.*lbf

71. Click here

    INSTALL SERVICE PLUG GRIP

    Click here

72. Click here

    ADD ENGINE OIL

    Click here

73. Click here

    ADD COOLANT (for Inverter)

    Click here

74. Click here

    ADD ENGINE COOLANT (for Engine)

    Click here

75. Click here

    INSPECT SHIFT LEVER POSITION

    Click here

76. Click here

    ADJUST SHIFT LEVER POSITION

    Click here

77. Click here

    INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

78. Click here

    INSPECT FOR COOLANT LEAK (for Engine)

    Click here

79. Click here

    INSPECT FOR OIL LEAK

80. Click here

    INSPECT FOR FUEL LEAK

    Click here

81. Click here

    INSPECT FOR EXHAUST GAS LEAK

82. Click here

    CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    for HFC-134a(R134a):Click here

    for HFO-1234yf(R1234yf):Click here

83. Click here

    WARM UP COMPRESSOR

    for HFC-134a(R134a):Click here

    for HFO-1234yf(R1234yf):Click here

84. Click here

    INSPECT FOR REFRIGERANT LEAK

    for HFC-134a(R134a):Click here

    for HFO-1234yf(R1234yf):Click here

85. Click here

    INSTALL FRONT WHEELS

    103 N*m

    1050 kgf*cm

    76 ft.*lbf

86. Click here

    PLACE FRONT WHEELS FACING STRAIGHT AHEAD

87. Click here

    INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

88. Click here

    PERFORM INITIALIZATION

    Click here

89. Click here

    INSPECT IGNITION TIMING

    Click here

90. Click here

    INSPECT ENGINE IDLE SPEED

    Click here

91. Click here

    INSPECT CO/HC

    Click here

92. Click here

    INSPECT ENGINE COOLANT LEVEL IN RESERVOIR (for Engine)

    Click here

93. Click here

    INSPECT COOLANT LEVEL IN RESERVE TANK (for Inverter)

    Click here

94. Click here

    CHECK ENGINE OIL LEVEL

    Click here

95. Click here

    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. Click here

    INSTALL FRONT SUSPENSION MEMBER BRACE

    
    

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

       52 N*m

       530 kgf*cm

       38 ft.*lbf

97. Click here

    INSTALL REAR ENGINE UNDER COVER LH

    
    

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

98. Click here

    INSTALL REAR ENGINE UNDER COVER RH

    Tip:

    Use the same procedure described for the LH side.

99. Click here

    INSTALL ENGINE UNDER COVER

    
    

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

100. Click here

     INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

     
     
     1. 

        *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. Click here

     INSTALL COOL AIR INTAKE DUCT SEAL

     Click here

102. Click here

     CHECK FOR SPEED SENSOR SIGNAL

     Click here