ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transaxle 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 Repairs" after replacing the engine assembly, cylinder head sub-assembly, camshaft, No. 2 camshaft, camshaft timing gear assembly, piston or piston ring.


PROCEDURE


  1. INSTALL DRIVE SHAFT BEARING BRACKET


    1. Install the drive shaft bearing bracket with the 3 bolts.

      Torque:
      63.7 N*m  { 650 kgf*cm, 47 ft.*lbf }

  2. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. Temporarily install the engine mounting insulator LH with the 4 bolts.

    2. B002HO4N01

      Tighten the 4 bolts in the sequence shown in the illustration.

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

  3. INSTALL ENGINE MOUNTING SPACER

    Tech Tips

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


    1. B002K37N01

      Temporarily install the engine mounting spacer with the 2 bolts.

    2. Tighten the 2 bolts in the sequence shown in the illustration.

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

  4. 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. B002HQRN01

      Temporarily install the engine mounting insulator sub-assembly RH with the 3 bolts.

    2. Tighten the 3 bolts in the sequence shown in the illustration.

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

    3. Install the radiator reservoir bracket with the bolt.

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

  5. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B002KA6N01

      Temporarily install the rear engine mounting insulator with the 2 bolts and 2 nuts.

    2. Tighten the 2 bolts and 2 nuts in the sequence shown in the illustration.

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

  6. INSTALL ENGINE HANGER

    Click here

  7. REMOVE ENGINE FROM ENGINE STAND

    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.

    • 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.


    1. Attach a sling device and hang the engine with a chain block.

    2. Lift the engine and remove it from the engine stand.

  8. FIX ENGINE ASSEMBLY

    Click here

  9. INSTALL ENGINE WIRE

  10. INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

  11. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY

    Click here

  12. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY

    Click here

  13. INSTALL TRANSMISSION OIL COOLER ASSEMBLY

    Click here

  14. CONNECT WIRE HARNESS

    Click here

  15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


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

    2. B002KIKC01
      *a Alignment Mark
      *b Protrusion

      Temporarily install the front suspension crossmember with the through bolt and nut.

      Tech Tips

      When installing the suspension crossmember, align the protrusion of the engine mounting bracket with the alignment mark of the engine mounting insulator.

    3. Place the engine on an engine lifter.

      Tech Tips

      Place the engine on wooden blocks or equivalent so that the engine is level.

      Note


      • Place the engine on wooden blocks or equivalent so that the engine is level.

      • B002HSMC02
        *1 No. 2 Motor Water Jacket Cover Assembly

        To prevent coolant leaks, do not position the height adjustment attachments or plate lift attachments under the No. 2 motor water jacket cover assembly.

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

      CAUTION:

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

      Note


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

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

    5. B002HTF

      Temporarily install the front suspension crossmember with the 2 bolts.

    6. B002KJ3

      Temporarily install the front suspension member rear brace RH and front suspension member rear brace LH with the 6 bolts.

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

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

      Note

      While holding the through bolt in place, tighten the nut.

    8. B002KB3C01
      *a Nut A
      *b Nut B
      *c Bolt

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

      Torque:
      for bolt and nut A
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      for nut B
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    9. B002HTF

      Tighten the 2 bolts.

      Torque:
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
    10. B002KJ3C01
      *a Bolt A
      *b Bolt B

      Tighten the 6 bolts.

      Torque:
      for bolt A
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
      for bolt B
      93 N*m  { 948 kgf*cm, 69 ft.*lbf }

    11. Remove the 2 bolts and 2 engine hangers.

    12. B002I5PC01
      *a Bolt A
      *b Bolt B

      Install the front crossmember with the 6 bolts.

      Torque:
      for bolt A
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }
      for bolt B
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    13. While holding the nut in place, tighten the through bolt of the rear engine mounting insulator.

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

      Tech Tips

      Check that the protrusion of the engine mounting bracket is aligned with the alignment mark of the engine mounting insulator.

    14. Tighten the through bolt and nut of the front engine mounting insulator.

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

      Note

      While holding the nut in place, tighten the through bolt.

  16. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  17. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  18. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  19. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover.

  20. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  21. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  22. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

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

    Click here

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

    Tech Tips

    Use the same procedure described for the LH side.

  25. CONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  26. CONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  27. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  28. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  29. CONNECT FRONT SPEED SENSOR LH


  30. CONNECT FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  31. INSTALL FRONT AXLE SHAFT NUT LH

    Click here

  32. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure described for the LH side.

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

    Click here

  34. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  35. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  36. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Connect the transmission control cable assembly to the control shaft lever with the nut.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Connect the transmission control cable assembly to the control cable bracket with a new clip.

    3. Connect the transmission control cable assembly to the hybrid transaxle assembly with the bolt.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    4. Connect the transmission control cable assembly to the rear engine mounting insulator with the bolt.

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

    5. Attach the clamp to connect the transmission control cable assembly to the bracket.

  37. CONNECT HEATER WATER OUTLET HOSE


    1. w/ EGR System:

      Connect the heater water outlet hose to the No. 1 EGR pipe, and slide the hose clamp to secure the hose.

    2. w/o EGR System:

      Connect the heater water outlet hose to the No. 3 water by-pass pipe, and slide the hose clamp to secure the hose.

  38. CONNECT HEATER WATER INLET HOSE


    1. Connect the heater water inlet hose to the cylinder head sub-assembly, and slide the hose clamp to secure the hose.

  39. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  40. CONNECT WIRE HARNESS


    1. Install the terminal to the No. 1 engine room relay block side cover.

    2. B002ISM

      Connect the 3 connectors and attach the 2 claws to connect the wire harness to the No. 1 engine room relay block.

    3. Install the nut.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
    4. B002HKT

      Attach the 3 wire harness clamps and connect the wire harness with the bolt.

      Torque:
      7.7 N*m  { 79 kgf*cm, 68 in.*lbf }

  41. CONNECT GROUND WIRE


    1. B002IU1

      Connect the ground wire with the bolt and attach the 2 wire harness clamps.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  42. INSTALL NO. 5 INVERTER COOLING HOSE


    1. Install the No. 5 inverter cooling hose to the motor cooling cooler, and slide the hose clip to secure the hose.

  43. INSTALL NO. 3 INVERTER COOLING HOSE


    1. Install the No. 3 inverter cooling hose to the hybrid vehicle transaxle, and slide the hose clip to secure the hose.

  44. CONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  45. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  46. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the cylinder head sub-assembly, and slide the hose clip to secure the hose.

  47. INSTALL RADIATOR HOSE HOSE CLAMP


    1. Install the radiator hose hose clamp.

  48. CONNECT NO. 2 RADIATOR HOSE


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

  49. INSTALL FAN AND GENERATOR V BELT

    Click here

  50. CONNECT RADIATOR RESERVOIR ASSEMBLY


    1. Connect the radiator reservoir assembly with the 2 bolts.

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

  51. INSTALL ECM

    Click here

  52. INSTALL INVERTER BRACKET ASSEMBLY


    1. Temporarily install the inverter bracket assembly with the 5 bolts.

    2. B002K7NN01

      Tighten the 5 bolts in the sequence shown in the illustration.

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

  53. INSTALL INVERTER WATER PUMP WITH MOTOR ASSEMBLY


    1. B002K3CC02
      *a Bolt A
      *b Bolt B

      Temporarily install the inverter water pump with motor assembly to the inverter bracket with bolt A.

    2. Install bolt B.

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

    3. Tighten bolt A.

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

  54. CONNECT NO. 2 FLOOR WIRE

    CAUTION:

    Be sure to wear insulated gloves.


    1. Connect the No. 2 floor wire to the hybrid vehicle transaxle assembly with the 2 clamps.

    2. Connect the No. 2 floor wire to the inverter bracket with the 2 clamps.

    3. Install the bolt.

      Torque:
      7.7 N*m  { 79 kgf*cm, 68 in.*lbf }

  55. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    Click here

  56. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case sub-assembly with the 2 bolts.

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

  57. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

  58. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  59. INSTALL SERVICE PLUG GRIP

    Click here

  60. INSTALL HYBRID BATTERY SERVICE PLUG COVER

    Click here

  61. INSTALL BATTERY SERVICE HOLE COVER

    Click here

  62. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  63. INSTALL DECK FLOOR BOX LH (w/ Spare Tire)

    Click here

  64. INSTALL REAR DECK FLOOR BOX (w/ Spare Tire)

    Click here

  65. INSTALL NO. 3 DECK BOARD SUB-ASSEMBLY (w/ Spare Tire)

    Click here

  66. ADD ENGINE OIL

    Click here

  67. ADD COOLANT (for Inverter Coolant)

    Click here

  68. ADD HYBRID TRANSAXLE FLUID

    Click here

  69. ADD ENGINE COOLANT

    Click here

  70. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


  71. INSPECT FOR FUEL LEAK

    Click here

  72. INSPECT FOR OIL LEAK

    Click here

  73. INSPECT FOR COOLANT LEAK

    Click here

  74. INSPECT FOR HYBRID TRANSAXLE FLUID

    Click here

  75. INSPECT FOR COOLANT LEAK (for Inverter Coolant)

    Click here

  76. INSPECT ENGINE OIL LEVEL

    Click here

  77. INSPECT ENGINE COOLANT LEVEL

    Click here

  78. INSPECT COOLANT LEVEL IN RESERVOIR TANK (for Inverter Coolant)

    Click here

  79. INSPECT HYBRID TRANSAXLE FLUID

    Click here

  80. INSPECT FOR EXHAUST GAS LEAK

    Click here

  81. INSPECT FOR REFRIGERANT LEAK


  82. INSPECT IGNITION TIMING

    Click here

  83. INSPECT ENGINE IDLE SPEED

    Click here

  84. INSPECT CO/HC

    Click here

  85. TEST MODE PROCEDURE (SPEED SENSOR)

    Click here

  86. ADJUST SHIFT LEVER POSITION

    Click here

  87. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  88. INSTALL FRONT FLOOR COVER CENTER LH

    Click here

  89. INSTALL REAR ENGINE UNDER COVER RH


    1. Install the rear engine under cover RH with the 2 clips.

  90. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the 2 clips.

  91. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY


    1. Install the No. 1 engine under cover assembly with the 2 screws, 4 bolts and 10 clips.

  92. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

  93. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. Align the 3 grommets of the No. 1 engine cover sub-assembly with the 3 pins, and install the No. 1 engine cover sub-assembly by pressing it.