Up to 08/2009

2GR-FXE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL FLYWHEEL SUB-ASSEMBLY Installation

2. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY Installation

3. INSTALL REAR ENGINE MOUNTING BRACKET

(a) Install the rear engine mounting bracket with the 3 bolts.

Torque : 64 Nm (652 kgf-cm, 47 ft-lbf)

4. INSTALL ELECTRIC INVERTER COMPRESSOR ASSEMBLY Installation

5. INSTALL V-RIBBED BELT Installation

6. INSTALL ENGINE MOUNTING BRACKET RH

(a) Install the engine mounting bracket RH with the 3 bolts.

Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

7. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY Installation

8. INSTALL FRONT ENGINE MOUNTING BRACKET Installation

9. INSTALL AUTOMATIC TRANSMISSION CASE COVER Installation

10. INSTALL NO. 3 AUTOMATIC TRANSMISSION CASE COVER Installation

11. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the bolt and nut.

Bolt - Torque : 34 Nm (347 kgf-cm, 25 ft-lbf)

Nut - Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

12. INSTALL RADIATOR PIPE CLAMP

(a) Install the radiator pipe clamp with the bolt.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

(b) Install the sensor wire and the breather plug hose to the radiator pipe clamp.

13. INSTALL ENGINE WIRE

(a) Install the engine wire to the engine with transaxle.

14. INSTALL FRONT ENGINE MOUNTING INSULATOR

(a) Install the front engine mounting insulator with the 3 bolts.

Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

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

(b) Install the 2 hole plugs.

15. INSTALL ENGINE MOUNTING INSULATOR LH

(a) Install the engine mounting insulator LH with the 3 bolts.

Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)

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

(b) Install the 2 hole plugs.

16. INSTALL ENGINE MOUNTING INSULATOR RH

(a) Install the engine mounting insulator RH with the 3 bolts.

Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)

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

(b) Install the 2 hole plugs.

17. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY

(a) Install the rear engine mounting insulator assembly with the 2 bolts.

Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

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

(b) Install the 2 hole plugs.

18. 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-lbf)

(b) Install the HV transaxle mass damper with the bolt.

Torque : 14 Nm (138 kgf-cm, 10 ft-lbf)

(c) Install the front engine mounting insulator with the nut.

Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)

(d) Install the rear engine mounting insulator assembly with the 2 bolts.

Torque : 75 Nm (765 kgf-cm, 55 ft-lbf)

(e) Connect the engine wire with the 2 clamps.

19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle on the engine lifter.

NOTICE:
* 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 frame assembly.
HINT
Place the engine on wooden blocks or equivalents so that the engine is level.

(b) Remove the 4 bolts and 2 engine hangers.

Text in Illustration

(c) Install the engine assembly with transaxle to the vehicle.

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

HINT
* 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.
(d) Install the front suspension member rear braces RH and LH with the 6 bolts and 2 nuts.

Bolt A - Torque : 85 Nm (867 kgf-cm, 62 ft-lbf)

Nut B - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

Bolt C - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

(e) Install the frame side rail plates RH and LH with the 6 bolts and 2 nuts.

Bolt D - Torque : 85 Nm (867 kgf-cm, 62 ft-lbf)

Nut E - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

Bolt F - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

(f) w/ Active Stabilizer System:

(1) Connect the 2 clamps.

(2) Connect the 2 front active stabilizer connectors.

20. INSTALL HEATER COVER (w/ Active Stabilizer System) Installation

21. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

22. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET

(a) Install the No. 1 exhaust pipe support bracket with the 2 nuts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

23. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING Reassembly

24. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

25. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

26. INSTALL FRONT LOWER SUSPENSION ARM LH Installation

27. INSTALL FRONT LOWER SUSPENSION ARM RH

HINT
Perform the same procedure as for the LH side.

28. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

29. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

30. CONNECT TIE ROD ASSEMBLY LH Installation

31. CONNECT TIE ROD ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

32. INSTALL FRONT SPEED SENSOR LH Installation

33. INSTALL FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

34. INSTALL FRONT AXLE SHAFT NUT LH Installation

35. INSTALL FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

36. INSTALL HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY (w/ Air Suspension)

(a) Install the height control sensor link sub-assembly LH and RH with the 2 nuts.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

37. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

38. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

39. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY Installation

40. CONNECT FUEL MAIN TUBE

(a) Push in the fuel tube connector to the fuel main tube until the fuel tube connector makes a "click" sound.

NOTICE:
* Check that there is no damage or foreign objects on the fuel tube connector.
* After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
(b) Install the No. 1 EFI fuel pipe clamp.

HINT
The half connection prevention connector prevents the fuel hose connector cover from being locked if the fuel tube is not securely connected.

41. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

(a) Remove the attached vinyl tape from the hose.

(b) Apply sufficient compressor oil to a new O-ring.

Compressor oil:

ND-OIL 8 or equivalent

(c) Install the O-ring onto the discharge hose sub-assembly.

(d) Connect the discharge hose sub-assembly with the nut.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

NOTICE:
Be sure to hold the discharge hose while tightening the nut so that the discharge hose is not deformed.

42. CONNECT SUCTION HOSE SUB-ASSEMBLY

(a) Remove the attached vinyl tape from the hose.

(b) Apply sufficient compressor oil to a new O-ring.

Compressor oil:

ND-OIL 8 or equivalent

(c) Install the O-ring onto the suction hose sub-assembly.

(d) Connect the suction hose sub-assembly with the nut.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

NOTICE:
Be sure to hold the suction hose while tightening the nut so that the suction hose is not deformed.

43. INSTALL ENGINE MOVING CONTROL ROD

(a) Temporarily install the engine moving control rod and engine mounting control bracket with the bolt A and bolt B.

Text in Illustration

(b) Install the engine mounting control bracket with the bolt C and bolt D.

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

(c) Install the engine moving control rod and engine mounting control bracket with the bolt A and bolt B.

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

44. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the No. 2 engine mounting stay RH with the bolt and 2 nuts.

Bolt - Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

Nut - Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)

45. CONNECT ENGINE WIRE

(a) Connect the connector to the ECU to lock the lever.

(b) Install the earth wire with the bolt.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

(c) Connect the 3 clamps.

(d) Connect the 3 wire connectors.

(e) Install the relay block cover to the relay block.

46. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

NOTICE:
Before installing the transmission control cable, check that the shift lever and neutral start switch are both in the N position.

(a) Fold back the boot on the transmission control cable assembly.

(b) Move the slider of the transmission control cable assembly as shown in the illustration to raise the lock piece.

Text in Illustration

(d) Install a new clip to the control cable bracket.

(e) Install the control cable to the control cable bracket.

Text in Illustration

NOTICE:
* 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.
(f) Move the control shaft lever to the N position.

(g) Connect the transmission control cable assembly to the control shaft lever with the nut.

Text in Illustration

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

NOTICE:
Check that the lock piece is protruding.

(h) Press in the lock piece of the transmission control cable assembly.

Text in Illustration

NOTICE:
Be sure to press the lock piece in until the lock of the slider is engaged.

(i) Put the boot back on the transmission control cable assembly.

47. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose.

48. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose.

49. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose.

50. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose.

(b) Install the No. 1 radiator hose to the radiator pipe clamp.

51. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose.

52. CONNECT NO. 3 MOTOR COOLING HOSE

(a) Connect the No. 3 motor cooling hose.

53. CONNECT NO. 1 MOTOR COOLING HOSE

(a) Connect the No. 1 motor cooling hose.

54. INSTALL INVERTER TRAY BRACKET SUB-ASSEMBLY

(a) Install the inverter tray bracket sub-assembly with the 5 bolts.

Torque : 17 Nm (173 kgf-cm, 12 ft-lbf)

55. INSTALL INVERTER WITH CONVERTER ASSEMBLY Installation

56. INSTALL CONDENSER Installation

57. INSTALL RADIATOR RESERVE TANK ASSEMBLY Installation

58. INSTALL NO. 4 INVERTER BRACKET Installation

59. CONNECT NO. 2 ENGINE ROOM WIRE Installation

60. CONNECT WATER HOSE Installation

61. CONNECT MG ECU CONNECTOR Installation

62. INSTALL RELAY BLOCK SUB-ASSEMBLY Installation

63. REMOVE INVERTER TERMINAL COVER Installation

64. CONNECT NO. 3 WIRE FRAME Installation

65. CONNECT NO. 1 CIRCUIT BREAKER SENSOR Installation

66. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR Installation

67. CONNECT NO. 3 WIRE FRAME (for AWD) Installation

68. CONNECT NO. 4 ENGINE WIRE Installation

69. CHECK HIGH VOLTAGE CABLE CONNECTION Installation

70. INSTALL INVERTER TERMINAL COVER Installation

71. INSTALL NO. 1 INVERTER RESERVE TANK BRACKET Installation

72. INSTALL INVERTER RESERVE TANK ASSEMBLY Installation

73. INSTALL NO. 3 INVERTER BRACKET Installation

74. INSTALL AIR CLEANER ASSEMBLY WITH HOSE

(a) Install the air cleaner assembly with hose with the 2 bolts.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

(b) Install the air cleaner hose with the band.

(c) Install the No. 1 fuel vapor feed hose to the air cleaner hose.

(d) Connect the air flow meter connector and harness clamp.

75. INSTALL INLET NO. 1 AIR CLEANER

(a) Install the inlet No. 1 air cleaner with the bolt.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(b) Connect the No. 1 fuel vapor feed hose to the clamp.

76. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Fit the 4 retainers and install the V-bank cover sub-assembly.

77. INSTALL INLET NO. 2 AIR CLEANER

(a) Install the inlet No. 2 air cleaner with the 2 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

78. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY

(a) Install the intake air resonator sub-assembly with the 2 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(b) Connect the 3 water hose clamps to the intake air resonator sub-assembly.

79. INSTALL SERVICE PLUG GRIP Installation

80. INSTALL BATTERY SERVICE HOLE COVER Installation

81. ADD ENGINE OIL Replacement

82. ADD HYBRID TRANSAXLE FLUID P313 Hybrid Transaxle

83. ADD COOLANT (for Engine) Service and Repair

84. ADD COOLANT (for Inverter) Service and Repair

85. CONNECT AUXILIARY BATTERY

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

86. INSTALL REAR DECK FLOOR BOX Installation

87. WARM UP ENGINE

88. INSPECT ENGINE OIL LEVEL Testing and Inspection

89. INSPECT COOLANT LEVEL IN RESERVOIR (for Engine) Testing and Inspection

90. INSPECT FOR COOLANT LEAK (for Inverter) Testing and Inspection

91. CHARGE WITH REFRIGERANT Service and Repair

92. INSPECT FOR FUEL LEAK Testing and Inspection

93. INSPECT FOR COOLANT LEAK (for Engine) Testing and Inspection

94. INSPECT AND ADJUST HYBRID TRANSAXLE FLUID P313 Hybrid Transaxle

95. INSPECT FOR OIL LEAK

96. INSPECT FOR REFRIGERANT LEAK Service and Repair

97. INSPECT FOR EXHAUST GAS LEAK

98. INSTALL FRONT FENDER APRON SEAL LH

99. INSTALL FRONT FENDER APRON SEAL RH

100. INSTALL FRONT FENDER LINER RH

101. INSTALL FRONT FENDER LINER LH

102. INSTALL NO. 2 ENGINE UNDER COVER

103. INSTALL NO. 1 ENGINE UNDER COVER

104. INSTALL FRONT WHEEL

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

105. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

106. INSPECT SHIFT LEVER POSITION Adjustments

107. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

HINT
Front Wheel Alignment.

108. INSPECT IGNITION TIMING Engine

109. INSPECT ENGINE IDLE SPEED Engine

110. INSPECT CO/HC Engine

111. PERFORM INITIALIZATION

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

112. CHECK VEHICLE HEIGHT (w/ Air Suspension)

NOTICE:
If the height control sensor link is removed, check the vehicle height.

(a) Change the height control switch from the "NORM" position to the "HIGH" position and back to the "NORM" position.

(b) Measure the vehicle height ( Front Wheel Alignment).

113. ADJUST VEHICLE HEIGHT (w/ Air Suspension)

NOTICE:
If the height control sensor has been replaced, be sure to adjust the vehicle height.

(a) Adjust the vehicle height ( Suspension Control System).

114. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

115. INSTALL FRONT SHOCK ABSORBER CAP LH (w/ Air Suspension) Installation

116. INSTALL FRONT SHOCK ABSORBER CAP RH (w/ Air Suspension)

HINT
Perform the same procedure as for the LH side.

117. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

118. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

119. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

120. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

121. INSTALL FRONT WIPER ARM HEAD CAP Installation

122. INSTALL FRONT FENDER TO COWL SIDE SEAL RH Installation

123. INSTALL FRONT FENDER TO COWL SIDE SEAL LH Installation

124. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH Installation

125. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH Installation

126. CHECK FOR SPEED SENSOR SIGNAL

HINT
Installation.

127. ADJUST HEADLIGHT ASSEMBLY (w/ Air Suspension)

(a) Adjust the headlight except LED Headlight Headlight Assembly (except LED Headlight).

(b) Adjust the headlight for LED Headlight Headlight Assembly (for LED Headlight).

128. INSTALL COOL AIR INTAKE DUCT SEAL

(a) Install the cool air intake duct seal with the 6 clips.

129. INSTALL ENGINE ROOM SIDE COVER

(a) Install the engine room side cover with the 4 clips.

130. INSTALL ENGINE ROOM SIDE COVER LH

(a) Install the engine room side cover with the 4 clips.