Engine Assembly: Installation
- INSTALL KNOCK CONTROL SENSOR (See INSTALLATION )
- INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
- Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent.
- Using a deep socket wrench 24 mm, install the oil pressure switch.
Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf)
- Apply adhesive to 2 or 3 threads of the oil pressure switch.
- INSTALL THERMOSTAT (See INSTALLATION )
- INSTALL WATER INLET (See INSTALLATION )
- INSTALL WATER INLET PIPE (See INSTALLATION )
- INSTALL INTAKE AIR CONNECTOR BRACKET NO.2
- 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 N*m (71 kgf*cm, 62 in.*lbf)
- 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.
- INSTALL COMPRESSOR MOUNTING BRACKET NO.1
- Temporarily install the mounting bracket with the 4 bolts.
- Install the mounting bracket by tightening the 4 bolts in the order shown in the illustration.
- INSTALL ENGINE MOUNTING STAY BRACKET
- Install the 3 bolts, nut and engine mounting stay bracket.
Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf)
- Install the 3 bolts, nut and engine mounting stay bracket.
- INSTALL ENGINE MOUNTING BRACKET RH
- Install the 3 bolts and engine mounting bracket RH.
Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf)
- Install the 3 bolts and engine mounting bracket RH.
- INSTALL ENGINE MOUNTING BRACKET REAR
- Install the 3 bolts and engine mounting bracket rear.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
- Install the 3 bolts and engine mounting bracket rear.
- INSTALL MANIFOLD STAY NO.2
- Install the 2 bolts and manifold stay No.2.
Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf)
- Install the 2 bolts and manifold stay No.2.
- INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2 (See INSTALLATION )
- INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2 (See INSTALLATION )
- INSTALL MANIFOLD CONVERTER INSULATOR NO.3 (See INSTALLATION )
- INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 N*m (80 kgf*cm, 71 in.*lbf)
- INSTALL WATER OUTLET (See INSTALLATION )
- INSTALL INTAKE MANIFOLD (See INSTALLATION )
- INSTALL INTAKE AIR SURGE TANK (See INSTALLATION )
- INSTALL EMISSION CONTROL VALVE SET (See INSTALLATION )
- INSTALL ENGINE HANGER NO.2
- Install the No.2 engine hanger in the correct direction shown in the illustration.
Torque: 20 N*m (199 kgf*cm, 14 ft.*lbf)
- Install the No.2 engine hanger in the correct direction shown in the illustration.
- REMOVE ENGINE STAND
- INSTALL FLYWHEEL SUB-ASSEMBLY (See INSTALLATION )
- INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY (See INSTALLATION )
- INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY (See INSTALLATION )
- INSTALL ENGINE MOUNTING BRACKET FRONT (See INSTALLATION )
- INSTALL FLYWHEEL HOUSING UNDER COVER (See INSTALLATION )
- INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See INSTALLATION )
- INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See INSTALLATION )
- INSTALL FRONT FRAME ASSEMBLY
- Install the engine mounting insulators RH and LH with the 2 nuts.
Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf)
- Install the engine mounting insulator FR with the nut.
Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf)
- Install the engine mounting insulator RR with the 2 bolts.
Torque: 75 N*m (765 kgf*cm, 55 ft.*lbf)
- Install the engine mounting insulators RH and LH with the 2 nuts.
- INSTALL HV TRANSAXLE MASS DAMPER
- Install the bolt and transaxle mass damper.
Torque: 14 N*m (138 kgf*cm, 10 ft.*lbf)
- Install the bolt and transaxle mass damper.
- INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (See INSTALLATION )
- INSTALL MANIFOLD STAY (See INSTALLATION )
- INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (See INSTALLATION )
- INSTALL ENGINE WIRE
- INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
- Set the engine assembly with transaxle on the engine lifter.
- Install the engine assembly to the vehicle.
- Install the frame side rail plates RH and LH with the 6 bolts and 2 nuts.
Torque: Bolt A
85 N*m (867 kgf*cm, 63 ft.*lbf)
Bolt B
32 N*m (326 kgf*cm, 24 ft.*lbf)
Nut C
32 N*m (326 kgf*cm, 24 ft.*lbf)
- Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.
Torque: Bolt A
85 N*m (867 kgf*cm, 63 ft.*lbf)
Bolt B
32 N*m (326 kgf*cm, 24 ft.*lbf)
Nut C
32 N*m (326 kgf*cm, 24 ft.*lbf)
- CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY (See INSTALLATION )
- INSTALL FRONT AXLE ASSEMBLY LH
- Install the drive shaft assembly LH to the front axle assembly LH.NOTE:
- Be careful not to damage the outboard joint boot.
- Be careful not to damage the speed sensor rotor.
- Install the drive shaft assembly LH to the front axle assembly LH.
- INSTALL FRONT AXLE ASSEMBLY RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH (See INSTALLATION )
- INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH
HINT:
Perform the same procedure as above on the opposite side.
- CONNECT TIE ROD END SUB-ASSEMBLY LH (See INSTALLATION )
- CONNECT TIE ROD END SUB-ASSEMBLY RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL SPEED SENSOR FRONT LH (See INSTALLATION )
- INSTALL SPEED SENSOR FRONT RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL FRONT AXLE HUB LH NUT (See INSTALLATION )
- INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See INSTALLATION )
- INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.3
- Using vernier calipers, measure the free length of the compression spring.
Minimum length:
41.5 mm (1.634 in.)
HINT:
If the free length is less than the minimum, replace the compression spring.
- Install a new gasket to the exhaust pipe front No. 3 as shown in the illustration.
- Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.
Torque: Bolt
48 N*m (490 kgf*cm, 35 ft.*lbf)
Nut
56 N*m (571 kgf*cm, 41 ft.*lbf)
- Connect the heated oxygen sensor connector.
- Using vernier calipers, measure the free length of the compression spring.
- INSTALL EXHAUST PIPE ASSEMBLY FRONT
- Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.
Torque: 56 N*m (571 kgf*cm, 41 ft.*lbf)
- Connect the heated oxygen sensor connector.
- Install 2 new gaskets and the exhaust pipe front No. 3 with the 2 bolts and 2 new nuts.
- CONNECT WIRE HARNESS
- Connect the power steering link connector and clamp.
- Install the ground cable.
- CONNECT ENGINE WIRE
- Install the 2 nuts and pull in the engine wire harness.
Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf)
- Connect the engine wire harness to the ECM and the junction block.
- Install the body ground and connector.
- Install the 2 nuts and pull in the engine wire harness.
- INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See INSTALLATION )
- INSTALL INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY NO.2 (See INSTALLATION )
- CONNECT WATER HOSE
- INSTALL HEATER WATER PUMP ASSEMBLY
- Install the bolt and heater water pump assembly.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
- Install the bolt and heater water pump assembly.
- CONNECT OIL COOLER INLET TUBE SUB-ASSEMBLY (W/ OIL COOLER)
- Using pliers, grip the claws of the clip and slide the clip to connect the oil cooler inlet tube.
- 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.
- CONNECT RADIATOR HOSE INLET
- CONNECT RADIATOR HOSE OUTLET
- CONNECT HEATER WATER INLET HOSE
- Using pliers, grip the claws of the clip and slide the clip to connect the heater water inlet hose.
- CONNECT HEATER WATER OUTLET HOSE
HINT:
Connection of the heater water outlet hose is the same as for the heater water inlet hose.
- CONNECT FUEL PIPE SUB-ASSEMBLY NO.1
- 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.
- Install the EFI fuel pipe clamp.
- INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY
- Install the control cable to the transaxle with the bolt.
Torque: 12 N*m (120 kgf*cm, 9 ft.*lbf)
- Install the control shaft lever with the nut.
Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf)
- Install the control cable and a new clip to the bracket.
- Install the control cable to the transaxle with the bolt.
- INSTALL INVERTER BRACKET NO.1
- Install the 4 bolts and inverter bracket.
Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf)
- Install the harness clamp and hose clamp.
- Install the 4 bolts and inverter bracket.
- INSTALL COMPRESSOR W7 MOTOR ASSEMBLY
- Temporarily install the compressor and magnetic clutch with the 3 bolts.
- Install the compressor and magnetic clutch by tightening the 3 bolts in the order shown in the illustration.
Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf)
- Connect the 2 connectors.
- INSTALL ENGINE MOUNTING STAY NO.2 RH (See INSTALLATION )
- INSTALL ENGINE MOVING CONTROL ROD (See INSTALLATION )
- INSTALL AIR CLEANER BRACKET
- Install the 2 bolts and air cleaner bracket.
Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
- Install the 2 bolts and air cleaner bracket.
- INSTALL RESERVOIR BRACKET
- Install the 2 bolts, nut and reservoir bracket.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
- Connect the clamp.
- Install the 2 bolts, nut and reservoir bracket.
- INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
- Install the 2 bolts and brake master cylinder reservoir to the bracket.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
- Connect the connector.
- Install the 2 bolts and brake master cylinder reservoir to the bracket.
- INSTALL W/ CONVERTER INVERTER ASSEMBLY (See INSTALLATION )
- INSTALL INVERTER BRACKET NO.4 (See INSTALLATION )
- INSTALL ENGINE ROOM RELAY BLOCK ASSEMBLY (See INSTALLATION )
- REMOVE INVERTER COVER (See INSTALLATION )
- INSTALL NO.3 WIRE FRAME (See INSTALLATION )
- INSTALL MG ECU CONNECTOR (See INSTALLATION )
- CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR (See INSTALLATION )
- INSTALL ENGINE WIRE NO.4 (See INSTALLATION )
- CHECK HIGH VOLTAGE CABLE CONNECTION (See INSTALLATION )
- INSTALL INVERTER COVER (See INSTALLATION )
- INSTALL POWER STEERING ECU BRACKET (See INSTALLATION )
- CONNECT WATER HOSE (See INSTALLATION )
- INSTALL INVERTER RESERVE TANK SUB-ASSEMBLY (See INSTALLATION )
- CONNECT ENGINE ROOM WIRE NO.2 (See INSTALLATION )
- CONNECT CIRCUIT BREAKER SENSOR NO.1 (See INSTALLATION )
- INSTALL POWER STEERING ECU ASSY (See INSTALLATION )
- INSTALL INVERTER BRACKET NO. 5 (See INSTALLATION )
- INSTALL AIR CLEANER CASE W/ RESONATOR (See INSTALLATION )
- INSTALL AIR CLEANER CAP W/ INLET
- Install the air cleaner filter element to the air cleaner case.
- Install the 2 bolts, 4 clamps and air cleaner cap w/ inlet.
Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)
- INSTALL COOL AIR INTAKE DUCT SEAL
- Install the 4 clips and cool air intake duct seal.
- INSTALL BATTERY CARRIER SUB-ASSEMBLY
- Install the 5 bolts and battery carrier.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
- Install the 5 bolts and battery carrier.
- INSTALL BATTERY
- Install the battery clamp and battery.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
- Install the battery clamp and battery.
- INSTALL SERVICE PLUG GRIP (See INSTALLATION )
- INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
- Remove the 4 shock absorber nuts.
- Install the 4 bolts, 2 nuts and cowl top panel sub-assembly.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
- Install the 4 shock absorber nuts (B).
Torque: 80 N*m (815 kgf*cm, 59 ft.*lbf)
- Install the wire harness clamp and grommet (A).
- INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See INSTALLATION )
- INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
- INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See INSTALLATION )
- INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See INSTALLATION )
- INSTALL FRONT WHEELS
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
- ADD AND INSPECT HYBRID TRANSAXLE FLUID (W/ O OIL COOLER) (See HYBRID TRANSAXLE FLUID )
- ADD AND INSPECT HYBRID TRANSAXLE FLUID (W7 OIL COOLER) (See HYBRID TRANSAXLE FLUID )
- ADD ENGINE OIL
- ADD COOLANT (for Inverter) (See REPLACEMENT )
- ADD COOLANT (for Engine) (See COOLANT (for Engine) )
- INSPECT FOR OIL LEAK
- INSPECT FOR COOLANT LEAK (for Inverter)
- INSPECT FOR COOLANT LEAK (for Engine) (See COOLING SYSTEM )
- INSPECT FOR FUEL LEAK (See ON-VEHICLE INSPECTION )
- INSPECT FOR EXHAUST GAS LEAK
- INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(See FRONT WHEEL ALIGNMENT )
- INSTALL ENGINE UNDER COVER NO.2
- Install the 2 bolts and engine under cover No.2.
- INSTALL FRONT FENDER APRON SEAL LH
- Install the 2 bolts, clip and fender apron seal LH.
- INSTALL FRONT FENDER APRON SEAL RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH
- Install the fender splash shield with the screw.
- INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL ENGINE UNDER COVER NO.1
- Install the 6 bolts, 2 screws, 2 clips and engine under cover.
- INSPECT STEERING WHEEL CENTER POINT
- INSPECT IGNITION TIMING (See ENGINE )
- INSPECT ENGINE IDLE SPEED (See ON-VEHICLE INSPECTION )
- INSPECT CO/HC (See ON-VEHICLE INSPECTION )
- CHECK ABS SPEED SENSOR SIGNAL
(See TEST MODE PROCEDURE )
- PERFORM INITIALIZATION
- Some system need initialization when reconnecting the cable from the battery terminal. (See INITIALIZATION )
- INSTALL ENGINE ROOM COVER SIDE
- Install the 5 clips and engine room cover side
- INSTALL ENGINE ROOM SIDE LH COVER NO.2
- Fit the clips and install the engine room side LH cover.