ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. Click here

   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. Click here

   INSTALL FLYWHEEL SUB-ASSEMBLY

   Click here

3. Click here

   INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY

   Click here

4. Click here

   INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY

   Click here

5. Click here

   INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

   Click here

6. Click here

   INSTALL DRIVE SHAFT BEARING BRACKET

   
   

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

      64 N*m

      653 kgf*cm

      47 ft.*lbf

7. Click here

   INSTALL ENGINE MOUNTING BRACKET RH

   
   

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

      54 N*m

      551 kgf*cm

      40 ft.*lbf

8. Click here

   TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR

   
   

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

      Tip:

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

9. Click here

   TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH

   
   

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

      Tip:

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

10. Click here

    TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH

    
    

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

       Tip:

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

11. Click here

    INSTALL FRONT FRAME ASSEMBLY

    
    

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

       95 N*m

       969 kgf*cm

       70 ft.*lbf

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

       95 N*m

       969 kgf*cm

       70 ft.*lbf

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

       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.

       Table 1. Text in Illustration

       *1	Front Engine Mounting Insulator	*2	Engine Mounting Insulator RH
       *3	Engine Mounting Insulator LH	-	-

       A
       58 N*m	591 kgf*cm	43 ft.*lbf
       B
       99 N*m	1010 kgf*cm	73 ft.*lbf

       Tip:

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

    5. 

       Install the 4 hole plugs.

       Table 2. Text in Illustration

       *1

       Engine Mounting Insulator RH

       *2

       Engine Mounting Insulator LH

       Tip:

       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.

       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. Click here

    INSTALL ENGINE WIRE

    
    

    1. Install the engine wire to the engine assembly.

13. Click here

    CONNECT WIRE HARNESS

    Click here

14. Click here

    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.

       • 

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

         Table 3. 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.

       Tip:
       

       • 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. 

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

       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.

       C
       85 N*m	867 kgf*cm	62 ft.*lbf
       D
       64 N*m	653 kgf*cm	47 ft.*lbf

       Tip:

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

15. Click here

    INSTALL FLYWHEEL HOUSING UNDER COVER

    
    

    1. Install the flywheel housing under cover.

16. Click here

    INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

17. Click here

    INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

18. Click here

    INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

19. Click here

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

    Click here

20. Click here

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

    Tip:

    Use the same procedure described for the LH side.

21. Click here

    CONNECT TIE ROD ASSEMBLY LH

    Click here

22. Click here

    CONNECT TIE ROD ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

23. Click here

    INSTALL FRONT SPEED SENSOR LH

    Click here

24. Click here

    INSTALL FRONT SPEED SENSOR RH

    Tip:

    Use the same procedure described for the LH side.

25. Click here

    INSTALL FRONT STABILIZER LINK ASSEMBLY LH

    Click here

26. Click here

    INSTALL FRONT STABILIZER LINK ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

27. Click here

    INSTALL FRONT AXLE SHAFT NUT LH

    Click here

28. Click here

    INSTALL FRONT AXLE SHAFT NUT RH

    Tip:

    Use the same procedure described for the LH side.

29. Click here

    CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

30. Click here

    INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

31. Click here

    CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

    Click here

32. Click here

    CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

33. Click here

    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.

       Tip:

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

34. Click here

    INSTALL ENGINE MOVING CONTROL ROD BRACKET

    
    

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

       
       
       1. 

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

       2. Fully tighten the 4 bolts.

          38 N*m

          387 kgf*cm

          28 ft.*lbf

       3. 

          Using SST, fully tighten the bolt.

          Table 4. Text in Illustration

          *a	Torque Wrench Fulcrum Length

          09961-00950

          Specified tightening torque
          52 N*m	530 kgf*cm	38 ft.*lbf

          Note:
          

          • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench (Click here).

          • When using SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 260 mm (10.2 in.)):

            33 N*m (337 kgf*cm, 24 ft.*lbf)

    2. 

       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.

          38 N*m

          387 kgf*cm

          28 ft.*lbf

35. Click here

    INSTALL EARTH WIRE

    
    

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

       8.0 N*m

       82 kgf*cm

       71 in.*lbf

36. Click here

    INSTALL NO. 2 ENGINE MOUNTING STAY RH

    
    

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

       38 N*m

       387 kgf*cm

       28 ft.*lbf

37. Click here

    CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

38. Click here

    CONNECT INLET HEATER WATER HOSE

    
    

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

39. Click here

    CONNECT OUTLET HEATER WATER HOSE

    
    

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

40. Click here

    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. Click here

    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. Click here

    CONNECT NO. 2 RADIATOR HOSE

    
    

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

43. Click here

    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. 

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

       Table 5. Text in Illustration

       *1	No. 1 Transmission Control Cable Assembly
       *2	No. 1 Transmission Control Cable Bracket
       *a	Claw A
       *b	Claw B

       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.

       12 N*m

       122 kgf*cm

       9 ft.*lbf

44. Click here

    CONNECT ENGINE WIRE

    
    
    1. 

       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.

       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. Click here

    INSTALL NO. 4 ENGINE WIRE

    
    

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

46. Click here

    INSTALL INVERTER WITH CONVERTER ASSEMBLY

    Click here

47. Click here

    CONNECT NO. 1 INVERTER COOLING HOSE ASSEMBLY

    Click here

48. Click here

    CONNECT NO. 4 INVERTER COOLING HOSE

    Click here

49. Click here

    CONNECT NO. 3 ENGINE ROOM WIRE

    Click here

50. Click here

    CONNECT LOW VOLTAGE CONNECTOR

    Click here

51. Click here

    REMOVE CONNECTOR COVER ASSEMBLY

    Click here

52. Click here

    CONNECT FRAME WIRE

    Click here

53. Click here

    CONNECT NO. 4 ENGINE WIRE

    Click here

54. Click here

    INSTALL CONNECTOR COVER ASSEMBLY

    Click here

55. Click here

    INSTALL NO. 3 MOTOR CABLE BRACKET

    Click here

56. Click here

    CONNECT MOTOR CABLE

    Click here

57. Click here

    INSTALL UPPER INVERTER COVER

    Click here

58. Click here

    CONNECT GENERATOR CABLE

    Click here

59. Click here

    INSTALL UPPER INVERTER COVER

    Click here

60. Click here

    INSTALL NO. 4 INVERTER BRACKET

    Click here

61. Click here

    INSTALL NO. 5 INVERTER BRACKET

    Click here

62. Click here

    INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    
    
    1. 

       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.

       Table 6. Text in Illustration

       *a	Projection

    2. Install the 2 bolts.

       5.0 N*m

       51 kgf*cm

       44 in.*lbf

63. Click here

    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. Click here

    INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

65. Click here

    INSTALL INLET AIR CLEANER ASSEMBLY

    
    

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

       8.0 N*m

       82 kgf*cm

       71 in.*lbf

66. Click here

    INSTALL SERVICE PLUG GRIP

    (Click here)

67. Click here

    ADD ENGINE OIL

    Click here

68. Click here

    ADD HYBRID TRANSAXLE FLUID

    Click here

69. Click here

    ADD COOLANT (for Inverter)

    Click here

70. Click here

    ADD COOLANT (for Engine)

    Click here

71. Click here

    CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

72. Click here

    WARM UP ENGINE

73. Click here

    INSPECT HYBRID TRANSAXLE FLUID

    Click here

74. Click here

    INSPECT ENGINE OIL LEVEL

    Click here

75. Click here

    INSPECT FOR FUEL LEAK

    Click here

76. Click here

    INSPECT FOR OIL LEAK

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 EXHAUST GAS LEAK

80. Click here

    INSPECT FOR REFRIGERANT LEAK

    Click here

81. Click here

    INSPECT IGNITION TIMING

    Click here

82. Click here

    INSPECT ENGINE IDLE SPEED

    Click here

83. Click here

    INSPECT CO/HC

    Click here

84. Click here

    INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

    
    

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

85. Click here

    INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

86. Click here

    INSPECT AND ADJUST SHIFT LEVER POSITION

    (Click here)

87. Click here

    INSTALL FRONT FENDER APRON SEAL LH

    
    

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

88. Click here

    INSTALL FRONT FENDER APRON SEAL RH

    
    

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

89. Click here

    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. Click here

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

    
    

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

91. Click here

    INSTALL FRONT WHEEL OPENING EXTENSION PAD LH

    
    

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

92. Click here

    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. Click here

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

    
    

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

94. Click here

    INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

    
    

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

95. Click here

    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. Click here

    INSTALL FRONT WHEEL

    103 N*m

    1049 kgf*cm

    76 ft.*lbf

97. Click here

    INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    (Click here)

98. Click here

    CHECK FOR SPEED SENSOR SIGNAL

    (Click here)