Engine Assembly, Installation

ENGINE ASSEMBLY

COMPONENTS:

INSTALLATION
1. INSTALL KNOCK CONTROL SENSOR

2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent.

b. Using a deep socket wrench 24 mm, install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
3. INSTALL THERMOSTAT
4. INSTALL WATER INLET
5. INSTALL WATER INLET PIPE

6. INSTALL INTAKE AIR CONNECTOR BRACKET NO. 2
a. Install the intake air connector bracket No. 2 with the 2 bolts. Using several steps, tighten the bolts uniformly in the sequence shown in the illustration.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
7. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1
a. Temporarily install the mounting bracket with the 4 bolts.

b. Install the mounting bracket by tightening the 4 bolts in the order shown in the illustration.

8. INSTALL ENGINE MOUNTING STAY BRACKET
a. Install the 3 bolts, nut and engine mounting stay bracket.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)

9. INSTALL ENGINE MOUNTING BRACKET RH
a. Install the 3 bolts and engine mounting bracket RH.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

10. INSTALL ENGINE MOUNTING BRACKET REAR
a. Install the 3 bolts and engine mounting bracket rear.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
11. INSTALL MANIFOLD STAY NO. 2
a. Install the 2 bolts and manifold stay No. 2.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
12. INSTALL EXHAUST MANIFOLD CONVERTER SUB ASSEMBLY NO. 2
13. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2
14. INSTALL MANIFOLD CONVERTER INSULATOR NO. 3
15. INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
16. INSTALL WATER OUTLET
17. INSTALL INTAKE MANIFOLD
18. INSTALL INTAKE AIR SURGE TANK
19. INSTALL EMISSION CONTROL VALVE SET

20. INSTALL ENGINE HANGER NO. 2
a. Install the No. 2 engine hanger in the correct direction shown in the illustration.
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)
21. REMOVE ENGINE STAND
22. INSTALL FLYWHEEL SUB-ASSEMBLY
23. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY
24. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY
25. INSTALL ENGINE MOUNTING BRACKET FRONT
26. INSTALL FLYWHEEL HOUSING UNDER COVER
27. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
28. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

29. INSTALL FRONT FRAME ASSEMBLY
a. Install the engine mounting insulators RH and LH with the 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)

b. Install the engine mounting insulator FR with the nut.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)

c. Install the engine mounting insulator RR with the 2 bolts.
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)

30. INSTALL HV TRANSAXLE MASS DAMPER
a. Install the bolt and transaxle mass damper.
Torque: 14 Nm (138 kgf-cm, 10 ft. lbs.)
31. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
32. INSTALL MANIFOLD STAY
33. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
34. INSTALL ENGINE WIRE

35. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine assembly with transaxle on the engine lifter.
b. Install the engine assembly to the vehicle.
c. Install the frame side rail plates RH and LH with the 6 bolts and 2 nuts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B 32 Nm (326 kgf-cm, 24 ft. lbs.)
Nut C 32 Nm (326 kgf-cm, 24 ft. lbs.)

d. Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B 32 Nm (326 kgf-cm, 24 ft. lbs.)
Nut C 32 Nm (326 kgf-cm, 24 ft. lbs.)
36. CONNECT STEERING INTERMEDIATE SHAFT SUB ASSEMBLY
37. INSTALL FRONT AXLE ASSEMBLY LH
a. Install the drive shaft assembly LH to the front axle assembly LH.

NOTICE:
^ Be careful not to damage the outboard joint boot.
^ Be careful not to damage the speed sensor rotor.

38. INSTALL FRONT AXLE ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

39. INSTALL FRONT SUSPENSION ARM SUBASSEMBLY LOWER NO. 1 LH
40. INSTALL FRONT SUSPENSION ARM SUB ASSEMBLY LOWER NO. 1 RH

HINT: Perform the same procedure as above on the opposite side.

41. CONNECT TIE ROD END SUB-ASSEMBLY LH
42. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

43. INSTALL SPEED SENSOR FRONT LH
44. INSTALL SPEED SENSOR FRONT RH

HINT: Perform the same procedure as above on the opposite side.

45. INSTALL FRONT AXLE HUB LH NUT
46. INSTALL FRONT AXLE HUB RH NUT

HINT: Perform the same procedure as above on the opposite side.

47. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
48. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

49. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3
a. Using vernier calipers, measure the free length of the compression spring.
Minimum length: 41.5 mm (1.634 inch)

HINT: If the free length is less than the minimum, replace the compression spring.

b. Install a new gasket to the exhaust pipe front No. 3 as shown in the illustration.

c. Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.
Torque:
Bolt 48 Nm (490 kgf-cm, 35 ft. lbs.)
Nut 56 Nm (571 kgf-cm, 41 ft. lbs.)
d. Connect the heated oxygen sensor connector.

50. INSTALL EXHAUST PIPE ASSEMBLY FRONT
a. Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.
Torque: 56 Nm (571 kgf-cm, 41 ft. lbs.)
b. Connect the heated oxygen sensor connector.
51. CONNECT WIRE HARNESS
a. Connect the power steering link connector and clamp.
b. Install the ground cable.
52. CONNECT ENGINE WIRE
a. Install the 2 nuts and pull in the engine wire harness.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
b. Connect the engine wire harness to the ECM and the junction block.
c. Install the body ground and connector.
53. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
54. INSTALL INSTRUMENT PANEL UNDER COVER SUB ASSEMBLY NO. 2
55. CONNECT WATER HOSE

56. INSTALL HEATER WATER PUMP ASSEMBLY
a. Install the bolt and heater water pump assembly.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

57. CONNECT OIL COOLER INLET TUBE SUB ASSEMBLY (W/OIL COOLER)
a. Using pliers, grip the claws of the clip and slide the clip to connect the oil cooler inlet tube.
58. CONNECT OIL COOLER OUTLET TUBE SUB ASSEMBLY (W/OIL COOLER)

HINT: Connection of the oil cooler outlet tube is the same as for the oil cooler inlet tube.

59. CONNECT RADIATOR HOSE INLET
60. CONNECT RADIATOR HOSE OUTLET

61. CONNECT HEATER WATER INLET HOSE
a. Using pliers, grip the claws of the clip and slide the clip to connect the heater water inlet hose.
62. CONNECT HEATER WATER OUTLET HOSE

HINT: Connection of the heater water outlet hose is the same as for the heater water inlet hose.

63. CONNECT FUEL PIPE SUB-ASSEMBLY NO. 1
a. Align the connector with the pipe, then push in the connector to the pipe until it makes a click sound to connect the fuel tube sub-assembly to the fuel delivery pipe.
b. Install the EFI fuel pipe clamp.

64. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY
a. Install the control cable to the transaxle with the bolt.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)

b. Install the control shaft lever with the nut.
Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.)
c. Install the control cable and a new clip to the bracket.

65. INSTALL INVERTER BRACKET NO. 1
a. Install the 4 bolts and inverter bracket.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
b. Install the harness clamp and hose clamp.
66. INSTALL COMPRESSOR W/MOTOR ASSEMBLY
a. Temporarily install the compressor and magnetic clutch with the 3 bolts.

b. Install the compressor and magnetic clutch by tightening the 3 bolts in the order shown in the illustration.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
c. Connect the 2 connectors.
67. INSTALL ENGINE MOUNTING STAY NO. 2 RH
68. INSTALL ENGINE MOVING CONTROL ROD

69. INSTALL AIR CLEANER BRACKET
a. Install the 2 bolts and air cleaner bracket.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)

70. INSTALL RESERVOIR BRACKET
a. Install the 2 bolts, nut and reservoir bracket.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
b. Connect the clamp.

71. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
a. Install the 2 bolts and brake master cylinder reservoir to the bracket.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
b. Connect the connector.
72. INSTALL W/CONVERTER INVERTER ASSEMBLY
73. INSTALL INVERTER BRACKET NO. 4
74. INSTALL ENGINE ROOM RELAY BLOCK ASSEMBLY
75. REMOVE INVERTER COVER
76. INSTALL NO. 3 WIRE FRAME
77. INSTALL MG ECU CONNECTOR
78. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR
79. INSTALL ENGINE WIRE NO. 4
80. CHECK HIGH VOLTAGE CABLE CONNECTION
81. INSTALL INVERTER COVER
82. INSTALL POWER STEERING ECU BRACKET
83. CONNECT WATER HOSE
84. INSTALL INVERTER RESERVE TANK SUBASSEMBLY
85. CONNECT ENGINE ROOM WIRE NO. 2
86. CONNECT CIRCUIT BREAKER SENSOR NO. 1
87. INSTALL POWER STEERING ECU ASSY
88. INSTALL INVERTER BRACKET NO. 5
89. INSTALL AIR CLEANER CASE W/RESONATOR
90. INSTALL AIR CLEANER CAP W/INLET
a. Install the air cleaner filter element to the air cleaner case.

b. Install the 2 bolts, 4 clamps and air cleaner cap w/inlet.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
91. INSTALL COOL AIR INTAKE DUCT SEAL
a. Install the 4 clips and cool air intake duct seal.

92. INSTALL BATTERY CARRIER SUB-ASSEMBLY
a. Install the 5 bolts and battery carrier.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
93. INSTALL BATTERY
a. Install the battery clamp and battery
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
94. INSTALL SERVICE PLUG GRIP
95. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
a. Remove the 4 shock absorber nuts.

b. Install the 4 bolts, 2 nuts and cowl top panel sub assembly.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
c. Install the 4 shock absorber nuts (B).
Torque: 80 Nm (815 kgf-cm, 59 ft. lbs.)
d. Install the wire harness clamp and grommet (A).
96. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
97. INSTALL COWL TOP VENTILATOR LOUVER SUB ASSEMBLY
98. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH
99. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH
100. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
101. ADD AND INSPECT HYBRID TRANSAXLE FLUID (W/O OIL COOLER)
102. ADD AND INSPECT HYBRID TRANSAXLE FLUID (W/OIL COOLER)
103. ADD ENGINE OIL
104. ADD COOLANT (HYBRID SIDE)
105. ADD COOLANT (ENGINE SIDE)
106. CHECK FOR ENGINE OIL LEAKS
107. CHECK FOR ENGINE COOLANT LEAKS (HYBRID SIDE)
108. CHECK FOR ENGINE COOLANT LEAKS (ENGINE SIDE)
109. CHECK FOR FUEL LEAKS
110. CHECK FOR EXHAUST GAS LEAKS
111. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
112. INSTALL ENGINE UNDER COVER NO. 2
a. Install the 2 bolts and engine under cover No. 2.

113. INSTALL FRONT FENDER APRON SEAL LH
a. Install the 2 bolts, clip and fender apron seal LH.
114. INSTALL FRONT FENDER APRON SEAL RH

HINT: Perform the same procedure as above on the opposite side.

115. INSTALL FRONT FENDER SPLASH SHIELD SUBASSEMBLY LH
a. Install the fender splash shield with the screw.
116. INSTALL FRONT FENDER SPLASH SHIELD SUBASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

117. INSTALL ENGINE UNDER COVER NO. 1
a. Install the 6 bolts, 2 screws, 2 clips and engine undercover.
118. INSPECT STEERING WHEEL CENTER POINT
119. INSPECT IGNITION TIMING
120. INSPECT ENGINE IDLE SPEED
121. INSPECT CO/HC
122. CHECK ABS SPEED SENSOR SIGNAL
123. PERFORM INITIALIZATION
a. Some system need initialization when reconnecting the battery cable. Testing and Inspection and/or Repair Instruction - Initialization

124. INSTALL ENGINE ROOM COVER SIDE
a. Install the 5 clips and engine room cover side

125. INSTALL ENGINE ROOM SIDE LH COVER
a. Fit the clips and install the engine room side LH cover.