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.

Tech Tips

Perform "Inspection After Repairs" after replacing the engine assembly, cylinder head sub-assembly camshaft, No. 2 camshaft, camshaft timing gear assembly, piston sub-assembly or piston ring Click here.

PROCEDURE


  1. INSTALL NO. 1 ENGINE HANGER

    Click here

  2. INSTALL ENGINE WIRE


    1. Connect all of the clamps and connectors and install the engine wire from the engine assembly.

  3. REMOVE ENGINE STAND


    1. Using a chain block and sling device, secure the engine assembly.

      Note


      • Make sure that the sling angle is correct to prevent the engine assembly and engine hangers from being damaged or deformed.

      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.

    2. Remove the engine stand from the engine.

  4. 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 5 bolts.

    2. B004168E03

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

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    3. Connect the wire harness clamp.

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

    2. B0040ZVE03

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

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  6. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. Gently place the engine assembly onto wood blocks or equivalent.

      Note


      • Set the engine assembly so that it is level.

      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.

      • This step should be done while hanging the engine assembly using the sling device and chain block.

    2. Install the flywheel sub-assembly Click here.

  7. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY


    1. Gently place the engine assembly onto wood blocks or equivalent.

      Note


      • Set the engine assembly so that it is level.

      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.

      • This step should be done while hanging the engine assembly using the sling device and chain block.

    2. Install the transmission input damper assembly Click here.

  8. INSTALL ENGINE ASSEMBLY


    1. B0040YPE04
      Text in Illustration
      *1 Knock Pin

      Make sure that the knock pins are installed to the engine.

    2. Temporarily install the hybrid vehicle transaxle assembly to the engine with the 2 bolts.

      Tech Tips

      Temporarily tighten bolt B first.

    3. Fully tighten the 2 bolts in the order of A and B.

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

      Note


      • Make sure that the wire harness or similar items are not pinched between the contact surfaces.

      • Do not forcibly pry on the hybrid vehicle transaxle.

      • Make sure to align the hybrid vehicle transaxle so that the input shaft of the hybrid vehicle transaxle will be inserted straight into the inner splines of the transmission input damper assembly.

      • Do not apply grease either to the inner splines of the transmission input damper assembly or to the outer splines of the input shaft.

      • When inserting the input shaft of the hybrid vehicle transaxle into the inner splines of the transmission input damper, do not shake the hybrid vehicle transaxle excessively.

      • When mounting the hybrid vehicle transaxle to the engine, make sure to securely fit the knock pins into the knock holes.

      • When tightening the bolts, be sure that the mating surfaces of the engine and the hybrid vehicle transaxle assembly are in close contact with one another.

      Bolt Length
      45 mm (1.77 in.)
    4. B0040YN

      Install the 4 bolts.

      Torque:
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }
      Bolt Length
      45 mm (1.77 in.)

    5. Engage the claw and install the flywheel housing side cover to the engine.

    6. Install the starter hole heat insulator to the engine with the 2 bolts.

      Torque:
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }
      Bolt Length
      45 mm (1.77 in.)

    7. Install the drive shaft heat insulator bracket to the engine with the 2 bolts.

      Torque:
      30 N*m  { 301 kgf*cm, 22 ft.*lbf }
      Bolt Length
      45 mm (1.77 in.)

    8. Connect the clamp to the drive shaft heat insulator bracket.

    9. Install the drive shaft heat insulator sub-assembly to the engine and drive shaft heat insulator bracket with the bolt and nut.

      Torque:
      18 N*m  { 179 kgf*cm, 13 ft.*lbf }
    10. B004135E04
      Text in Illustration
      *1 Wire Harness Clamp Bracket
      *2 Transmission Control Cable Clamp

      Install the 2 wire harness clamp brackets and transmission control cable clamp to the hybrid vehicle transaxle assembly with the 3 bolts.

      Torque:
      Bolt A
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      Bolt B
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    11. Connect the 7 clamps, 4 connectors and install the wire harness to the hybrid vehicle transaxle assembly with the 3 bolts.

      B00415K
      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
    12. B0040YQ

      Connect the 4 clamps and No. 2 engine wire.

  9. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Using a sling device and chain block, set the engine assembly with transaxle on the engine lifter.

      Note


      • Place the height adjustment attachment and plate lift attachment so that the engine assembly with transaxle is level.

      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.

      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments onto the No. 2 oil pan sub-assembly of the engine assembly.

      • Do not place any attachments onto the drain plug and rear cover plug of the hybrid vehicle transaxle assembly.

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

    2. Remove the 2 bolts and 2 No. 1 engine hangers.

    3. Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulator sub-assembly RH and engine mounting insulator LH can be installed.

      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.

    4. Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the front suspension crossmember can be installed.

    5. By inserting SST into the datum holes in the front suspension crossmember RH and LH alternately, temporarily install the front suspension crossmember with the 6 bolts.

      B00414PE03
      Text in Illustration
      *a CORRECT *b INCORRECT
      *c Datum Hole - -
      SST
      09670-00010

    6. Connect the engine mounting insulator LH with the bolt and nut to the engine assembly.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    7. Connect the engine mounting insulator sub-assembly RH with the bolt and 2 nuts to the engine assembly.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    8. B0040Z5E03

      Using several steps, uniformly tighten the 6 bolts.

      Torque:
      Bolt A
      87 N*m  { 887 kgf*cm, 64 ft.*lbf }
      Bolt B
      151 N*m  { 1539 kgf*cm, 111 ft.*lbf }
      Bolt C
      98 N*m  { 999 kgf*cm, 72 ft.*lbf }

  10. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover.

  11. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  12. INSTALL NO. 2 ENGINE ROOM RELAY BLOCK AND NO. 2 JUNCTION BLOCK ASSEMBLY

    Click here

  13. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  14. INSTALL FRONT FLOOR CENTER BRACE

    Click here

  15. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  16. CONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  17. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  18. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  19. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  20. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  21. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  22. CONNECT ENGINE WIRE (for RHD)


    1. B0040ZD

      Connect the wire harness clamp.

    2. Connect the engine wire to the engine room main wire.

    3. Connect the engine wire to the engine room relay block and junction block assembly and engage the claw.

    4. Connect the 2 wire harness clamps and 2 connectors.

    5. B004162

      Connect the ECM connector and lower the lever.

      Note


      • When connecting the connector, make sure that dirt, water or other foreign matter does not become stuck between the connector and other part.

      • Make sure that the lever is securely locked.

  23. CONNECT ENGINE WIRE (for LHD)


    1. B0040ZD

      Connect the wire harness clamp.

    2. Connect the engine wire to the engine room main wire.

    3. Connect the engine wire to the engine room relay block and junction block assembly and engage the claw.

    4. Connect the 2 wire harness clamps and 2 connectors.

    5. B004109

      Connect the 2 wire harness clamps.

    6. Connect the ECM connector and lower the lever.

      Note


      • When connecting the connector, make sure that dirt, water or other foreign matter does not become stuck between the connector and other part.

      • Make sure that the lever is securely locked.

  24. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  25. INSTALL EFI FUEL PIPE CLAMP

    Click here

  26. INSTALL NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the 2 hose clamps and install the No. 1 fuel vapor feed hose.

  27. CONNECT HEATER WATER HOSE


    1. Connect the 2 heater water hoses.

  28. CONNECT NO. 2 RADIATOR HOSE


    1. B0040WQE02
      Text in Illustration
      *a Up
      *b for LH Side
      *c Do Not Position Hose Clamp Claws In This Area

      Connect the No. 2 radiator hose.

      Tech Tips

      Make sure that the claws on the hose clamp are positioned as shown in the illustration.

  29. CONNECT NO. 1 RADIATOR HOSE


    1. B0040Z8E02
      Text in Illustration
      *a Up
      *b for LH Side
      *c Do Not Position Hose Clamp Claws In This Area

      Connect the No. 1 radiator hose.

      Tech Tips

      Make sure that the claws on the hose clamp are positioned as shown in the illustration.

  30. INSTALL INVERTER BRACKET ASSEMBLY

    CAUTION:

    Wear insulated gloves.


    1. Temporarily install the inverter bracket assembly with the 4 bolts.

    2. B00414FE03

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

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    3. Connect the ground wire with the bolt.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

    4. Install the inverter reservoir tank assembly with the 2 bolts.

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

    5. Connect the 2 wire harness clamps.

    6. Connect the motor cable protector with the bolt.

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

  31. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  32. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    B0040YCE03
    Text in Illustration
    *a Engine Side
    *b 75°

    1. Install the air cleaner hose sub-assembly and lock the hose clamp.

      Note


      • Align the groove of the air cleaner hose with the tab of the throttle body with motor assembly and install the hose.

      • Make sure that the tab of the air cleaner hose clamp stays within the range shown by *b.

    2. Install the air cleaner cap sub-assembly with the 2 clamps.

    3. Connect the wire harness clamp and mass air flow meter connector.

    4. Connect the No. 1 fuel vapor feed hose and No. 2 fuel vapor feed hose.

    5. Connect the purge VSV connector and wire harness clamp.

    6. Connect the hose clamp and ventilation hose.

  33. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    Click here

  34. INSTALL OUTER COWL TOP PANEL (for LHD)

    Click here

  35. INSTALL OUTER COWL TOP PANEL (for RHD)

    Click here

  36. INSTALL INNER COWL TOP TO COWL BRACE (for LHD)

    Click here

  37. INSTALL INNER COWL TOP TO COWL BRACE (for RHD)

    Click here

  38. INSTALL FRONT NO. 1 VENTILATOR SEAL (for LHD)

    Click here

  39. INSTALL FRONT NO. 1 VENTILATOR SEAL (for RHD)

    Click here

  40. INSTALL FRONT AIR SHUTTER SEAL RH (for LHD)

    Click here

  41. INSTALL FRONT AIR SHUTTER SEAL RH (for RHD)

    Click here

  42. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  43. ADD COOLANT (for Engine)

    Click here

  44. ADD COOLANT (for Inverter)

    Click here

  45. ADD HYBRID TRANSAXLE FLUID

    Click here

  46. INSPECT HYBRID TRANSAXLE FLUID

    Click here

  47. ADD ENGINE OIL

    Click here

  48. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

    Click here

  49. INSTALL SERVICE PLUG GRIP

    Click here

  50. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  51. WARM UP COMPRESSOR

    Click here

  52. INSPECT FOR REFRIGERANT LEAK

    Click here

  53. CHECK ENGINE OIL LEVEL

    Click here

  54. INSPECT FOR FUEL LEAK

    Click here

  55. INSPECT FOR COOLANT LEAK (for Engine)

    Click here

  56. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  57. INSPECT FOR HYBRID TRANSAXLE FLUID LEAK

  58. INSPECT FOR OIL LEAK

  59. INSPECT FOR EXHAUST GAS LEAK

  60. INSPECT IGNITION TIMING

    Click here

  61. INSPECT ENGINE IDLE SPEED

    Click here

  62. INSPECT CO/HC

    Click here

  63. INSPECT SHIFT LEVER POSITION

    Click here

  64. ADJUST SHIFT LEVER POSITION

    Click here

  65. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  66. CHECK ABS SPEED SENSOR SIGNAL

    Click here

  67. INSTALL NO. 2 CYLINDER HEAD COVER (w/ No. 2 Cylinder Head Cover)

    Click here

  68. INSTALL ENGINE UNDER COVER RH

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

  69. INSTALL ENGINE UNDER COVER LH

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