ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:


  • The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.

  • To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

PROCEDURE


  1. INSTALL ENGINE HANGERS

    Click here

  2. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  3. INSTALL ONE-WAY CLUTCH HOLDING PLATE

    Click here

  4. INSTALL ONE-WAY CLUTCH ASSEMBLY

    Click here

  5. INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

  6. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY

    Click here

  7. INSTALL ENGINE ASSEMBLY

    Click here

  8. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly with transaxle.

  9. INSTALL STARTER HOLE INSULATOR

    Click here

  10. 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. B006HE5C01
      *a Bolt
      *b Nut

      Install the engine mounting insulator sub-assembly RH with the 2 bolts and nut.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

      Note

      Temporarily tighten the bolt (A), and then fully tighten the 2 bolts and nut in the order of (B), (A) and (C).

    2. B006IJ5

      Install the No. 2 earth wire to the engine mounting insulator sub-assembly RH and vehicle body with the 2 bolts.

      Torque:
      10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

  11. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B006HOCC01
      *a Bolt
      *b Nut

      Install the engine mounting insulator LH with the 4 bolts and nut.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

      Note

      Temporarily tighten the bolt (A), and then fully tighten the 4 bolts and nut in the order of (B), (C), (D), (A) and (E).

  12. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front suspension crossmember sub-assembly level, set an engine lifter underneath the engine assembly with transaxle and front suspension crossmember sub-assembly.

      Note


      • 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 to or removed from an engine stand.

      • To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.

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

    3. Install the wiring harness clamp bracket to the cylinder head sub-assembly with the bolt.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    4. Engage the 3 clamps.

    5. Operate the engine lifter and install the engine assembly with transaxle to the vehicle.

      CAUTION:

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

      Note


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

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

    6. Connect the front suspension crossmember sub-assembly to the vehicle with the 4 bolts.

      Torque:
      141 N*m  { 1438 kgf*cm, 104 ft.*lbf }
    7. B006IUNC27
      *a Adhesive

      Apply adhesive to 2 or 3 threads at the end of each of the bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
    8. B006HYJ

      Install the No. 2 engine mounting stay LH with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    9. B006HR8C01
      *a Bolt
      *b Nut

      Connect the engine mounting insulator LH to the hybrid vehicle transaxle assembly with the 3 bolts and nut.

      Torque:
      Bolt
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }
      Nut
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    10. B006IUU

      Connect the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 2 bolts.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

    11. Install the nut.

      Torque:
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

    12. Connect the 2 cooler brackets to the engine mounting insulator sub-assembly RH with the bolt and nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

  13. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  14. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  15. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING

    Click here

  16. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  17. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

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

    Click here

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

    Tech Tips

    Use the same procedure as for the LH side.

  20. INSTALL FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  21. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  22. CONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  23. CONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  24. INSTALL FRONT SPEED SENSOR LH

    Click here

  25. INSTALL FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure as for the LH side.

  26. INSTALL FRONT AXLE SHAFT NUT LH

    Click here

  27. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure as for the LH side.

  28. CONNECT OUTLET NO. 1 OIL COOLER HOSE


    1. Connect the outlet No. 1 oil cooler hose to the hybrid vehicle transaxle assembly and slide the clip to secure it.

  29. CONNECT INLET NO. 1 OIL COOLER HOSE


    1. Connect the inlet No. 1 oil cooler hose to the hybrid vehicle transaxle assembly and slide the clip to secure it.

  30. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

    Click here

  31. INSTALL FRONT CENTER FLOOR BRACE

    Click here

  32. INSTALL FRONT FLOOR COVER LH

    Click here

  33. INSTALL FRONT FLOOR COVER RH

    Tech Tips

    Use the same procedure as for the LH side.

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

    Click here

  35. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  36. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  37. CONNECT NO. 3 ENGINE WIRE


    1. Connect the No. 3 engine wire to hybrid vehicle transaxle assembly with the bolt.

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

    2. Engage the clamp.

  38. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY


    1. Type A:


      1. B006HKAN01

        Install the compressor with motor assembly with the 3 bolts.

        Torque:
        25 N*m  { 255 kgf*cm, 18 ft.*lbf }

        Tech Tips

        Tighten the 3 bolts in the order shown in the illustration.

    2. Type B:


      1. Using an E8 "TORX" socket wrench, temporarily install the compressor with motor assembly with the 2 stud bolts.

        Torque:
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      2. B006IEHN01

        Install the compressor with motor assembly with the bolt and 2 nuts.

        Torque:
        25 N*m  { 255 kgf*cm, 18 ft.*lbf }

        Tech Tips

        Tighten the bolt and nuts in the order shown in the illustration.

    3. B006HTUC02
      *a Connector (A)
      *b Connector (B)
      *c Green-colored Lock

      Connect connector (B).

    4. Connect connector (A) and slide the green-colored lock as shown in the illustration to lock it securely.

      CAUTION:

      Make sure to wear insulating gloves.

      Note

      Make sure that the connector is connected securely.

    5. Connect the bracket with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  39. CONNECT OUTLET NO. 1 HYBRID WATER PUMP HOSE


    1. Connect the outlet No. 1 hybrid water pump hose to the motor cooling cooler and slide the clip to secure it.

  40. CONNECT INLET HYBRID RADIATOR HOSE


    1. Connect the inlet hybrid radiator hose to the motor cooling cooler and slide the clip to secure it.

  41. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  42. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the No. 1 fuel vapor feed hose to the fuel vapor feed pipe and slide the clip to secure it.

  43. CONNECT INLET HEATER WATER HOSE A


    1. Connect the inlet heater water hose A to the EGR valve assembly and slide the clip to secure it.

  44. CONNECT OUTLET HEATER WATER HOSE E


    1. Connect the outlet heater water hose E to the No. 1 water by-pass pipe and slide the clip to secure it.

  45. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the water inlet sub-assembly and slide the clip to secure it.

  46. CONNECT NO. 3 RADIATOR HOSE


    1. Connect the No. 3 radiator hose to the water outlet and slide the clip to secure it.

    2. Install the 2 bolts to the hybrid vehicle transaxle assembly.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  47. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    Click here

  48. INSTALL INLET NO. 1 AIR CLEANER

    Click here

  49. INSTALL AIR CLEANER BRACKET

    Click here

  50. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  51. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  52. INSTALL THROTTLE BODY ASSEMBLY

    Click here

  53. INSTALL INLET NO. 2 AIR CLEANER

    Click here

  54. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

  55. CONNECT NO. 8 WATER BY-PASS HOSE


    1. Connect the No. 8 water by-pass hose to the No. 2 water by-pass hose assembly and slide the clip to secure it.

  56. ADD ENGINE OIL

    Click here

  57. ADD HYBRID TRANSAXLE FLUID

    Click here

  58. ADD ENGINE COOLANT (for Engine)

    Click here

  59. CHECK ENGINE OIL LEVEL

    Click here

  60. INSPECT HYBRID TRANSAXLE FLUID

    Click here

  61. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  62. INSPECT FOR COOLANT LEAK (for Engine)

    Click here

  63. CHECK FUEL LEAK

    Click here

  64. INSPECT FOR OIL LEAK

    Click here

  65. INSPECT FOR EXHAUST GAS LEAK

    Click here

  66. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 3 bolts.

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

  67. INSTALL REAR ENGINE UNDER COVER LH


    1. except Rough Road Area Specification Vehicles:


      1. Install the rear engine under cover LH with the 4 clips and screw.

    2. for Rough Road Area Specification Vehicles:


      1. Install the rear engine under cover LH with the 5 clips and screw.

  68. INSTALL REAR ENGINE UNDER COVER RH


    1. except Rough Road Area Specification Vehicles:


      1. Install the rear engine under cover RH with the 4 clips and screw.

    2. for Rough Road Area Specification Vehicles:


      1. Install the rear engine under cover RH with the 5 clips and screw.

  69. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY


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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  70. INSTALL FRONT WHEELS

    Click here

  71. INSPECT IGNITION TIMING

    Click here

  72. INSPECT ENGINE IDLE SPEED

    Click here

  73. INSPECT CO/HC

    Click here

  74. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  75. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. Engage the 3 clips to install the No. 1 engine cover sub-assembly.

      Note


      • Be sure to engage the clips securely.

      • Do not apply excessive force or hit the No. 1 engine cover sub-assembly to engage the clips. This may cause the No. 1 engine cover sub-assembly to break.

  76. CHECK SPEED SENSOR SIGNAL

    Click here