Engine - Installation

Engine









WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. NOTE: Due to packaging requirements, the correct bolt must be used at the damper locations.

NOTE: The damper contains a clutch which is designed to slip briefly during vehicle operation. It is essential that no grease, oil or cleaning solvents be allowed to contaminate the slip clutch. Do not use grease on transmission input shaft. Should the damper become contaminated, it must be replaced.

Install the transaxle damper.

- Tighten to 29 Nm (21 lb-ft).





2. NOTE: When positioning the engine to the transaxle, care must be taken to maintain alignment of the damper spline with the transaxle input shaft.

NOTE: Transaxle removed from view for clarity.

Using the Heavy Duty Floor Crane and Spreader Bar, position the engine and transaxle together. Install the 6 transaxle-to-engine bolts.

- Tighten to 48 Nm (35 lb-ft).





3. Connect the 2 heater hoses to the coolant outlet.





4. Install the 2 engine cover studs onto the valve cover studs.





5. Position the auxiliary coolant pump and bracket and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).





6. Using the Heavy Duty Floor Crane and Engine Lifting Bracket, position the engine and transaxle onto the Powertrain Lift.

7. NOTE: Due to the weight of the transaxle, special care should be taken to mount the powertrain securely to the Powertrain Lift.

Using the Universal Adapter Brackets, secure the engine to the Powertrain Lift.





8. Raise the engine and transaxle into the vehicle.

9. Install the 3 nuts on the upper transaxle insulator.
- Tighten to 90 Nm (66 lb-ft).





10. Install the engine mount bracket and 3 nuts.
- Tighten to 103 Nm (76 lb-ft).





11. Install the engine mount bracket bolt.
- Tighten to 115 Nm (85 lb-ft).





12. Install the 2 transaxle-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





13. Install the 2 transaxle-to-engine bolts.
- Tighten to 48 Nm (35 lb-ft).





14. Connect the brake booster vacuum hose.





15. Connect the 2 engine wiring harness connectors and attach the wiring retainer.





16. Connect the 2 transaxle electrical connectors.





17. Position the master cylinder reservoir and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





18. Connect the transaxle harness electrical connector, attach the wiring retainer and install the bolt.
- Tighten to 10 Nm (89 lb-in).





19. Connect the Motor Electronics Cooling System (MECS) coolant expansion tank hose.





20. Install the MECS coolant expansion tank nut and bolt.
- Tighten to 10 Nm (89 lb-in).





21. Connect the upper Evaporative Emission (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to Fuel System - General Information Quick Connect Coupling.





22. Connect the fuel supply tube.





23. Connect the engine wiring harness connector and attach it to the bracket.





24. Attach the engine wiring harness retainer to the bracket.





25. Connect the 2 heater hoses.





26. Attach the 2 block heater (if equipped) and the high voltage electrical system wiring retainers to the valve cover stud bolts.





27. Connect the 2 vehicle high voltage electrical system electrical connectors.
- Attach the wiring harness retainer.





28. Install a new gasket and connect the A/C tube to the A/C condenser.
- Install the nut.

- Tighten to 15 Nm (133 lb-in).





29. Install a new gasket and connect the A/C tube to the A/C compressor.
- Install the nut.

- Tighten to 15 Nm (133 lb-in).





30. Install the A/C tube bracket bolt.
- Tighten to 6 Nm (53 lb-in).





31. Install the A/C tube bracket bolt to the strut tower.
- Tighten to 6 Nm (53 lb-in).





32. Install a new gasket and connect the A/C tube.
- Install the nut.

- Tighten to 15 Nm (133 lb-in).





33. If equipped, attach the 3 block heater wiring retainers.





34. NOTE: Lower radiator hose shown, upper similar.

Connect the upper and lower radiator hoses and install the retaining clips.





35. NOTE: Lubricate the oil filter O-ring with clean engine oil before installation.

Tighten the oil filter three-fourths of a turn after the oil filter gasket makes contact with the oil filter adapter.





36. Attach the transaxle shift cable routing retainer to the transaxle.





37. Position the selector lever cable bracket in place and install the 2 nuts.
- Tighten to 12 Nm (106 lb-in).





38. Connect the selector lever cable end to the manual control lever. Check selector lever cable adjustment. For additional information, refer to Automatic Transaxle/Transmission External Controls - Hybrid Adjustments.





39. Install the transaxle ground wire and nut.
- Tighten to 10 Nm (89 lb-in).





40. Connect the transaxle coolant temperature sensor and the Transmission Range (TR) sensor electrical connectors.
- Attach the wiring harness retainer.





41. Connect the vacuum pump assembly electrical connector and attach the wiring retainer.





42. Place the subframe assembly on the Powertrain Lift and raise the subframe into the installed position.

43. NOTE: LH shown, RH similar.

Install the front subframe nuts.

- Tighten to 150 Nm (111 lb-ft).





44. NOTE: LH shown, RH similar.

Position the subframe brackets and install the bolts finger-tight.





45. NOTE: LH shown, RH similar.

Install the subframe nuts.

- Tighten to 150 Nm (111 lb-ft).





46. NOTE: LH shown, RH similar.

Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).





47. Connect the MECS electrical connector and attach the pump to the bracket.





48. Attach the 3 wiring harness retainers (2 shown) to the LH front of the subframe.





49. Attach the auxiliary coolant hose retainer to the subframe.





50. Connect the 2 Electronic Power Assist Steering (EPAS) electrical connectors near the front of the subframe.
- Attach the connector retainer from the subframe.





51. NOTE: RH shown, LH similar.

Install the stabilizer bar links and nuts to the struts.

- Tighten to 40 Nm (30 lb-ft).





52. NOTE: RH shown, LH similar.

Install tie-rod ends and nuts.

- Tighten to 48 Nm (35 lb-ft).

- Install the cotter pin.





53. Install the engine roll restrictor bolt.
- Tighten to 90 Nm (66 lb-ft).





54. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips (2 shown) into the body.
- From under the vehicle, verify that the seal is correctly installed on the steering gear and the 4 retaining clips are fully engaged into the dash.





55. Install the LH splash shield and the 6 pin-type retainers (4 shown).





56. Position the LH fender splash shield and install the 4 screws.





57. Install the EPAS wiring ground wire and bolt in the RH front wheel well.
- Tighten to 10 Nm (89 lb-in).





58. Install the RH splash shield and the 6 pin-type retainers (4 shown).





59. Position the RH fender splash shield and install the 4 screws.





60. Install the exhaust flexible pipe. For additional information, refer to Exhaust System Exhaust Flexible Pipe.

61. Install the front wheels and tires. For additional information, refer to Wheels and Tires Removal and Replacement.

62. Fill the engine with clean engine oil.

63. If equipped, install the underbody cover and 7 screws.





64. Connect the steering column shaft to the steering gear and install the bolt.
- Tighten to 20 Nm (177 lb-in).





65. Install the steering joint cover and the 2 nuts.





66. Repower the vehicle high-voltage electrical system. For additional information, refer to High Voltage Traction Battery High-Voltage Traction Battery Systems Depowering.

67. Connect the battery ground cable. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.

68. Install the engine Air Cleaner (ACL) outlet pipe. For additional information, refer to Intake Air Distribution and Filtering - Hybrid Air Cleaner Outlet Pipe.

69. Reset the Passive Anti-Theft System (PATS). For additional information, refer to Anti-Theft - Passive Anti-Theft System (PATS) Testing and Inspection.

70. Fill and bleed the MECS. For additional information, refer to Transaxle/Transmission Cooling - Hybrid Motor Electronics Cooling System Draining and Filling.

71. Fill and bleed the cooling system. For additional information, refer to Engine Cooling - Hybrid Service and Repair.

72. Recharge the A/C system. For additional information, refer to Climate Control System - General Information and Diagnostics - Hybrid Air Conditioning (A/C) System Recovery, Evacuation and Charging.