ENGINE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL FLYWHEEL SUB-ASSEMBLY


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

      Note

      This step should be done while hanging the engine assembly using the engine hangers and a chain block.

    2. Install the flywheel sub-assembly Click here.

  2. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY


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

      Note

      This step should be done while hanging the engine assembly using the engine hangers and a chain block.

    2. Install the transmission input damper assembly Click here.

  3. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY


    1. Install the hybrid vehicle transaxle assembly Click here.

      Note

      Be careful not to apply excess force to the transmission input damper assembly when removing or installing the hybrid vehicle transaxle assembly. If excess force is applied, the transmission input damper assembly may be damaged, or its splines may become misaligned.

  4. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine.

  5. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  6. INSTALL STARTER HOLE INSULATOR

    Click here

  7. INSTALL RADIATOR PIPE


    1. Install the radiator pipe with the 2 bolts.

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

    2. Install the No. 3 radiator hose with the clamp.

  8. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

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


    1. A005APSE03

      Position the engine mounting insulator sub-assembly RH as shown in the illustration.

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

    3. Tighten the 3 bolts to install the engine mounting insulator sub-assembly RH in the order of the bolt B, bolt C and bolt A.

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

    4. Connect the earth wire clamp to the engine mounting insulator sub-assembly RH.

    5. Install the 2 cooler brackets with the 2 bolts.

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

  9. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A005AC5E03

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

    2. Tighten the 4 bolts to install the engine mounting insulator LH in the order of the bolt C, bolt B, bolt D and bolt A.

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

  10. INSTALL REAR ENGINE MOUNTING INSULATOR


    1. Install the rear engine mounting insulator to the engine mounting bracket with the through bolt.

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

      Tech Tips

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

  11. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. A005B3D

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

      Tech Tips

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

  12. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


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

      Note


      • Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.

      • Do not position a height adjustment attachment or plate lift attachment onto the front cross member sub-assembly.

      Tech Tips

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

    2. Remove the 2 bolts and 2 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 insulators RH and 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.

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

    4. Install the front crossmember with the 4 bolts.

      Torque:
      96 N*m  { 979 kgf*cm, 71 ft.*lbf }
    5. A0059O9

      Install the front engine mounting insulator to the front crossmember with the 2 bolts.

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

      Tech Tips

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

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

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

      Note

      When installing the engine mounting insulator, tighten the nut while holding the bolt.

    7. A005AZJE01

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

      Torque:
      Nut A
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      Nut B
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
      Bolt
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    8. Tighten the front engine mounting insulator with the bolt and nut.

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

  13. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  14. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  15. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  16. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  17. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Click here

  18. INSTALL FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT

    Click here

  19. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  20. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH

    Tech Tips

    Perform the same procedure as for the LH side.

  21. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  22. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

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

    Click here

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

    Tech Tips

    Perform the same procedure as for the LH side.

  25. INSTALL FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  26. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  27. CONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  28. CONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  29. INSTALL FRONT SPEED SENSOR LH

    Click here

  30. INSTALL FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  31. INSTALL FRONT AXLE SHAFT NUT LH

    Click here

  32. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  33. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/ Exhaust Heat Recirculation System)

    Click here

  34. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/o Exhaust Heat Recirculation System)

    Click here

  35. INSTALL FRONT CENTER FLOOR BRACE

    Click here

  36. INSTALL FRONT NO. 3 ENGINE UNDER COVER

    Click here

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

    Click here

  38. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for LHD)

    Click here

  39. INSTALL COLUMN HOLE COVER SILENCER SHEET (for LHD)

    Click here

  40. CONNECT ENGINE WIRE


    1. Connect the engine wire with the 2 clamps.

    2. Install the earth wire with the bolt.

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

    3. Connect the wire harness with the 3 clamps.

    4. A0059R8

      Connect the wire harness to the engine room junction block.

    5. Connect the 2 connectors and 2 clamps to the engine room junction block.

    6. A005AZ5

      Connect the connector to the ECM with the lock lever.

    7. Connect the 2 clamps.

  41. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

    Click here

  42. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube connector and fuel pipe.

      CAUTION:

      Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.

    2. Install the No. 1 fuel pipe clamp.

  43. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the No. 1 fuel vapor feed hose with the clamp.

  44. CONNECT HEATER HOSE


    1. Connect the heater hose with the clamp.

  45. CONNECT INLET HEATER WATER HOSE


    1. Connect the inlet heater water hose with the clamp.

  46. CONNECT OUTLET HEATER WATER HOSE


    1. Connect the outlet heater water hose with the clamp.

  47. CONNECT NO. 5 INVERTER COOLING HOSE


    1. Connect the No. 5 inverter cooling hose with the clamp.

  48. CONNECT NO. 3 INVERTER COOLING HOSE


    1. Connect the No. 3 inverter cooling hose with the clamp.

  49. CONNECT NO. 4 WATER BY-PASS HOSE


    1. Connect the No. 4 water by-pass hose with the clamp.

  50. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose with the clamp.

  51. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose with the clamp.

  52. INSTALL INVERTER TRAY BRACKET


    1. A005AUKE04

      Position the inverter tray bracket as shown in the illustration.

    2. Temporarily install the inverter tray bracket with the 5 bolts.

    3. Tighten the 5 bolts to install the inverter tray bracket in the order of the bolt A, bolt C, bolt D, bolt E and bolt B.

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

    4. Connect the 2 clamps to the inverter tray bracket.

  53. INSTALL INVERTER RESERVE TANK ASSEMBLY


    1. A005ACDE03

      Temporarily install the inverter reserve tank assembly with the 2 bolts.

    2. Tighten the 2 bolts to install the inverter reserve tank assembly in the order of the bolt B and bolt A.

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

  54. INSTALL INVERTER WITH CONVERTER ASSEMBLY

    Click here

  55. CONNECT WATER HOSE

    Click here

  56. CONNECT NO. 2 ENGINE ROOM WIRE

    Click here

  57. REMOVE INVERTER COVER

    Click here

  58. CONNECT NO. 2 ENGINE WIRE

    Click here

  59. CONNECT MOTOR CABLE

    Click here

  60. CONNECT GENERATOR CABLE

    Click here

  61. CONNECT FRAME WIRE

    Click here

  62. CHECK HIGH VOLTAGE CABLE CONNECTION

    Click here

  63. INSTALL INVERTER COVER

    Click here

  64. CONNECT ENGINE ROOM MAIN WIRE

    Click here

  65. INSTALL NO. 1 INVERTER BRACKET

    Click here

  66. INSTALL AIR CLEANER HOSE ASSEMBLY

    Click here

  67. INSTALL AIR CLEANER CASE


    1. A005AQ6

      Install the air cleaner case with the 3 bolts.

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

    2. Connect the No. 4 water by-pass hose to the air cleaner case with the 3 clamps.

    3. Install the air cleaner filter element.

  68. INSTALL INLET AIR CLEANER ASSEMBLY


    1. Install the inlet air cleaner assembly with the 3 bolts.

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

    2. Connect the No. 4 water by-pass hose to the inlet air cleaner assembly with the clamp.

  69. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Install the air cleaner filter element.

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

    3. Connect the air flow meter connector.

  70. INSTALL SERVICE PLUG GRIP

    Click here

  71. ADD HYBRID TRANSAXLE FLUID

    Click here

  72. INSPECT HYBRID TRANSAXLE FLUID

    Click here

  73. ADD COOLANT (for Engine)

    Click here

  74. ADD COOLANT (for Inverter)

    Click here

  75. ADD ENGINE OIL

    Click here

  76. INSPECT ENGINE OIL LEVEL

    Click here

  77. INSPECT FOR FUEL LEAK

    Click here

  78. INSPECT FOR COOLANT LEAK (for Engine)

    Click here

  79. INSPECT FOR COOLANT LEAK (for Inverter)

    Click here

  80. INSPECT FOR OIL LEAK

  81. INSPECT FOR EXHAUST GAS LEAK

  82. INSTALL NO. 2 ENGINE UNDER COVER

  83. INSTALL NO. 1 ENGINE UNDER COVER

  84. INSTALL FRONT LOWER BUMPER ABSORBER

  85. INSTALL REAR ENGINE UNDER COVER LH

  86. INSTALL REAR ENGINE UNDER COVER RH

  87. INSTALL FRONT WHEELS

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

  88. CHECK FRONT WHEELS FACING STRAIGHT AHEAD

  89. INSPECT IGNITION TIMING

    Click here

  90. INSPECT ENGINE IDLE SPEED

    Click here

  91. INSPECT CO/HC

    Click here

  92. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  93. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

  94. INSTALL NO. 2 CYLINDER HEAD COVER


    1. Engage the 3 clips to install the cover.

      Note


      • Be sure to engage the clips securely.

      • Do not apply excessive force or hit the cover to engage the clips. This may cause the cover to break.

  95. CHECK ABS SPEED SENSOR SIGNAL

    Click here