ENGINE ASSEMBLY INSTALLATION

Info Added 2017-08-02

CAUTION / NOTICE / HINT

Tech Tips

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

PROCEDURE


  1. REMOVE ENGINE STAND


    1. Using an engine sling device and engine lift, secure the engine assembly.

      Note


      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hanger from deforming or becoming damaged.

      • 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.

    2. Remove the engine stand from the engine assembly.

  2. INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

  3. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY

    Click here

  4. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY

    Click here

  5. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  6. INSTALL DRIVE SHAFT BEARING BRACKET


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

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  7. INSTALL ENGINE MOUNTING BRACKET RH


    1. Install the engine mounting bracket RH with the 3 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  8. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Temporarily install the front engine mounting insulator with the 3 nuts.

      Tech Tips

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

  9. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH


    1. Temporarily install the engine mounting insulator LH with the 3 nuts.

      Tech Tips

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

  10. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH


    1. Temporarily install the engine mounting insulator RH with the 3 nuts.

      Tech Tips

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

  11. INSTALL FRONT FRAME ASSEMBLY


    1. Install the engine mounting insulator LH with the nut.

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

    2. Install the engine mounting insulator RH with the nut.

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

    3. Install the front engine mounting insulator with the bolt.

      Torque:
      87 N*m  { 887 kgf*cm, 64 ft.*lbf }

    4. Fully tighten the 9 temporarily installed nuts of the engine mounting insulators to the specified torque.

      A0003Z1E22
      Text in Illustration
      *1 Front Engine Mounting Insulator *2 Engine Mounting Insulator RH
      *3 Engine Mounting Insulator LH - -
      Torque:
      A
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }
      B
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

      Tech Tips

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

    5. Install the 4 hole plugs.

      A000554E13
      Text in Illustration
      *1 Engine Mounting Insulator RH *2 Engine Mounting Insulator LH

      Tech Tips

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

    6. Install the wire harness clamp bracket to the front frame assembly with the bolt.

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

    7. Engage the 2 clamps to connect the No. 4 engine wire from the front engine mounting insulator.

  12. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  13. CONNECT WIRE HARNESS

    Click here

  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine assembly with transaxle on an engine lifter.

      Note


      • Install height adjustment attachments and plate lift attachments under the engine assembly with transaxle.

      • To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle.

      • Make sure to support the engine assembly with transaxle securely to prevent it from falling.

      • A000485E01

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

        Text in Illustration
        *1 No. 2 Motor Water Jacket Cover Assembly

    2. Remove the engine hangers Click here.

    3. Install the engine assembly with transaxle to the vehicle.

      Note

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

      Tech Tips


      • Make sure that the engine 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.

    4. A0004UYE19

      Install the frame side rail plate RH and frame side rail plate LH with the 4 bolts and 2 nuts.

      Torque:
      A
      85 N*m  { 867 kgf*cm, 62 ft.*lbf }
      B
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

    5. Install the front suspension member brace rear RH and front suspension member brace rear LH with the 4 bolts and 2 nuts.

      Torque:
      C
      85 N*m  { 867 kgf*cm, 62 ft.*lbf }
      D
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

      Tech Tips

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

  15. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover.

  16. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  17. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  18. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

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

    Click here

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

    Tech Tips

    Use the same procedure described for the LH side.

  21. CONNECT TIE ROD ASSEMBLY LH

    Click here

  22. CONNECT TIE ROD ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  23. INSTALL FRONT SPEED SENSOR LH

    Click here

  24. INSTALL FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  25. INSTALL FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  26. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  27. INSTALL FRONT AXLE SHAFT NUT LH

    Click here

  28. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure described for the LH side.

  29. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  30. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  31. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

    Click here

  32. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  33. INSTALL ENGINE MOVING CONTROL ROD


    1. Temporarily install the engine moving control rod and No. 3 engine mounting stay RH to the engine moving control rod bracket with the bolt.

      Tech Tips

      Perform this procedure only when replacement of the engine moving control rod is necessary.

  34. INSTALL ENGINE MOVING CONTROL ROD BRACKET


    1. When the engine moving control rod has been replaced.


      1. A0005TA

        Temporarily install the engine moving control rod bracket with the 4 bolts.

      2. Fully tighten the 4 bolts.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      3. A0003J5E01

        Using SST, fully tighten the bolt.

        SST
        09961-00950
        Torque:
        without SST
        52 N*m  { 530 kgf*cm, 38 ft.*lbf }
        with SST
        33 N*m  { 337 kgf*cm, 24 ft.*lbf }

        Note


        • The "with SST" torque value is effective when using SST with a fulcrum length of 150 mm (5.91 in.) and a torque wrench with a fulcrum length of 260 mm (10.2 in.) Click here.

        • The "with SST" torque value is effective when SST is parallel to the torque wrench.

    2. A0005TA

      When the engine moving control rod has been reused.


      1. Temporarily install the engine moving control rod bracket with the 4 bolts.

      2. Fully tighten the 4 bolts.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  35. INSTALL EARTH WIRE


    1. Install the earth wire to the engine moving control rod bracket with the bolt.

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

  36. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. Install the No. 2 engine mounting stay RH with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  37. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  38. CONNECT INLET HEATER WATER HOSE


    1. Connect the inlet heater water hose and slide the clip to secure it.

  39. CONNECT OUTLET HEATER WATER HOSE


    1. Connect the outlet heater water hose and slide the clip to secure it.

  40. CONNECT NO. 5 INVERTER COOLING HOSE


    1. Connect the No. 5 inverter cooling hose to the hybrid vehicle transaxle assembly and slide the clip to secure it.

  41. CONNECT NO. 1 RADIATOR HOSE


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

    2. Connect the air fuel ratio sensor wire to the No. 1 radiator hose with the hose clamp.

  42. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose and slide the clip to secure it.

  43. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Connect the transmission control cable assembly to the 2 transmission control cable brackets.

    2. Install a new clip to the No. 1 transmission control cable bracket.

    3. A0008FME06
      Text in Illustration
      *1 No. 1 Transmission Control Cable Assembly
      *2 No. 1 Transmission Control Cable Bracket
      *a Claw A
      *b Claw B

      Install the transmission control cable assembly to the No. 1 transmission control cable bracket.

      Note


      • Make sure that the claws A on the clip are securely fit into the bracket holes.

      • Make sure that the cable is securely installed inside of the claws B of the clip.

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

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

  44. CONNECT ENGINE WIRE


    1. A0008OX

      Connect the wire harness clamp.

    2. Connect the ECM connector with the lock lever.

    3. Install the wire harness and wire harness bracket with the 2 bolts.

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

    4. Engage the wire harness clamp to connect the engine wire to the engine room relay block.

    5. Connect the 4 connectors.

    6. Install the No. 1 relay block cover.

  45. INSTALL NO. 4 ENGINE WIRE


    1. Engage the 2 wire harness clamps to connect the No. 4 engine wire to the fan shroud.

  46. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    Click here

  47. CONNECT NO. 1 INVERTER COOLING HOSE ASSEMBLY

    Click here

  48. CONNECT NO. 4 INVERTER COOLING HOSE

    Click here

  49. CONNECT NO. 3 ENGINE ROOM WIRE

    Click here

  50. CONNECT LOW VOLTAGE CONNECTOR

    Click here

  51. REMOVE CONNECTOR COVER ASSEMBLY

    Click here

  52. CONNECT FRAME WIRE

    Click here

  53. CONNECT NO. 4 ENGINE WIRE

    Click here

  54. INSTALL CONNECTOR COVER ASSEMBLY

    Click here

  55. INSTALL NO. 3 MOTOR CABLE BRACKET

    Click here

  56. CONNECT MOTOR CABLE

    Click here

  57. INSTALL UPPER INVERTER COVER

    Click here

  58. CONNECT GENERATOR CABLE

    Click here

  59. INSTALL UPPER INVERTER COVER

    Click here

  60. INSTALL NO. 4 INVERTER BRACKET

    Click here

  61. INSTALL NO. 5 INVERTER BRACKET

    Click here

  62. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A0003Y5E03
      Text in Illustration
      *a Projection

      Insert the projection of the air cleaner case sub-assembly into the hole of the No. 2 air cleaner bracket as shown in the illustration.

    2. Install the 2 bolts.

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

  63. INSTALL AIR CLEANER FILTER ELEMENT


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

      Note

      Install the air cleaner filter element with the printed side facing the vehicle left.

  64. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  65. INSTALL INLET AIR CLEANER ASSEMBLY


    1. Install the inlet air cleaner assembly with the 2 bolts.

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

  66. INSTALL SERVICE PLUG GRIP

    Click here

  67. ADD ENGINE OIL

    Click here

  68. ADD HYBRID TRANSAXLE FLUID

    Click here

  69. ADD COOLANT (for Inverter)

    Click here

  70. ADD COOLANT (for Engine)

    Click here

  71. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  72. WARM UP ENGINE

  73. INSPECT HYBRID TRANSAXLE FLUID

    Click here

  74. INSPECT ENGINE OIL LEVEL

    Click here

  75. INSPECT FOR FUEL LEAK

    Click here

  76. INSPECT FOR OIL LEAK

  77. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  78. INSPECT FOR COOLANT LEAK (for Engine)

    Click here

  79. INSPECT FOR EXHAUST GAS LEAK

  80. INSPECT FOR REFRIGERANT LEAK

    Click here

  81. INSPECT IGNITION TIMING

    Click here

  82. INSPECT ENGINE IDLE SPEED

    Click here

  83. INSPECT CO/HC

    Click here

  84. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


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

  85. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

  86. INSPECT AND ADJUST SHIFT LEVER POSITION

    Click here

  87. INSTALL FRONT FENDER APRON SEAL LH


    1. Install the front fender apron seal LH with the 2 bolts and clip.

  88. INSTALL FRONT FENDER APRON SEAL RH


    1. Install the front fender apron seal RH with the 2 bolts and clip.

  89. INSTALL ENGINE UNDER COVER LH (w/o Front Lower Bumper Absorber)


    1. Install the engine under cover LH with the 2 screws and 2 clips.

  90. INSTALL ENGINE UNDER COVER LH (w/ Front Lower Bumper Absorber)


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

  91. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH


    1. Install the front wheel opening extension pad LH with the 3 screws.

  92. INSTALL ENGINE UNDER COVER RH (w/o Front Lower Bumper Absorber)


    1. Install the engine under cover RH with the 2 screws and 3 clips.

  93. INSTALL ENGINE UNDER COVER RH (w/ Front Lower Bumper Absorber)


    1. Install the engine under cover RH with the 3 clips.

  94. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH


    1. Install the front wheel opening extension pad RH with the 3 screws.

  95. INSTALL FRONT LOWER BUMPER ABSORBER (w/ Front Lower Bumper Absorber)


    1. Install the front lower bumper absorber with the 6 bolts and 6 screws.

  96. INSTALL FRONT WHEEL

    Torque:
    103 N*m  { 1049 kgf*cm, 76 ft.*lbf }

  97. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  98. CHECK FOR SPEED SENSOR SIGNAL

    Click here