INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with hybrid vehicle transaxle assembly is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

PROCEDURE

1. INSTALL STUD BOLT

(a) Using a E8 "TORX" socket wrench, install the 2 stud bolts to the hybrid vehicle transaxle assembly.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

2. INSTALL TRANSAXLE HOUSING PLUG

(a) Install the transaxle housing plug and a new gasket to the hybrid vehicle transaxle assembly. Torque: 39.2 N·m {400 kgf·cm, 29 ft·lbf}

3. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the 2 wire harness clamp brackets to the hybrid vehicle transaxle assembly with the 2 bolts.

Torque:

12.5 N·m {127 kgf·cm, 9 ft·lbf}

4. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET

(a) Install the No. 1 transmission control cable bracket to the hybrid vehicle transaxle assembly with the 2 bolts.

Torque:

12 N·m {122 kgf·cm, 9 ft·lbf}

5. INSTALL HOSE BRACKET

(a) Install the hose bracket to the hybrid vehicle transaxle assembly with the 2 bolts.

Torque:

11.5 N·m {117 kgf·cm, 8 ft·lbf}

6. INSTALL NO. 1 MOTOR COOLING PIPE

(a) Temporarily install the No. 1 motor cooling pipe to the union with the flare nut.

(b) Install the No. 1 oil cooler tube clamp to the hose bracket with the bolt.

Torque:

11.5 N·m {117 kgf·cm, 8 ft·lbf}

(c) Using a 17 mm union nut wrench, tighten the flare nut to install the No. 1 motor cooling pipe. Torque: Specified Tightening Torque : 34.3 N·m {350 kgf·cm, 25 ft·lbf} HINT: Calculate the torque wrench reading when changing the fulcrum length of the torque wrench. Click here When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 29.4 N*m (300 kgf*cm, 22 ft.*lbf)

*a Torque Wrench Fulcrum Length

7. INSTALL MOTOR COOLING COOLER

(a) Temporarily install the motor cooling cooler with No. 2 motor cooling pipe to the hybrid vehicle transaxle assembly with the 3 bolts.

(b) Tighten the 3 bolts in the order shown in the illustration.

Torque:

11.5 N·m {117 kgf·cm, 8 ft·lbf}

(c) Temporarily install the No. 2 motor cooling pipe to the hybrid vehicle transaxle assembly with the union bolt and a new gasket.

(d) Install the No. 1 oil cooler tube clamp to the hose bracket with the bolt.

Torque:

11.5 N·m {117 kgf·cm, 8 ft·lbf}

(e) Tighten the union bolt to install the No. 2 motor cooling pipe.

Torque:

35 N·m {357 kgf·cm, 26 ft·lbf}

(f) Connect the No. 1 motor cooling hose to the No. 1 motor cooling pipe and slide the clip to secure it. NOTICE: Make sure to align the paint mark on the No. 1 motor cooling pipe with the paint mark on the No. 1 motor cooling hose.

*a 2 to 7 mm (0.0787 to 0.276 in.) *b Paint Mark

8. INSTALL MOTOR CABLE

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9. INSTALL NO. 2 ENGINE MOVING CONTROL ROD

(a) Install the No. 2 engine moving control rod to the hybrid vehicle transaxle assembly with the 4 bolts. Torque: 44 N·m {449 kgf·cm, 32 ft·lbf} NOTICE: Temporarily tighten the bolt (A), and then fully tighten the 4 bolts in the order of (B), (C) and (A).

10. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Install the front suspension crossmember sub-assembly to the No. 2 engine moving control rod with the bolt.

Torque:

170 N·m {1734 kgf·cm, 125 ft·lbf}

11. INSTALL ENGINE ASSEMBLY

(a) Make sure that the knock pins are installed to the engine assembly.

*1 Knock Pin

(b) Install the engine assembly to the hybrid vehicle transaxle assembly with the 7 bolts. Torque: 33 N·m {337 kgf·cm, 24 ft·lbf} NOTICE: When tightening the bolts, be sure that the contact surfaces of the engine assembly and hybrid vehicle transaxle assembly are in close contact with one another. Temporarily tighten the bolt (A), and then fully tighten the 7 bolts in the order of (B), (A) and (C). Do not apply grease to the inner splines of the transmission input damper assembly or input shaft assembly. Make sure that the wire harness or similar items are not pinched between the contact surfaces. Do not use excessive force when installing the engine assembly. Make sure to align the hybrid vehicle transaxle assembly so that the input shaft assembly of the hybrid vehicle transaxle assembly will be inserted straight into the inner splines of the transmission input damper assembly. When inserting the input shaft assembly of the hybrid vehicle transaxle assembly into the inner splines of the transmission input damper assembly, do not shake the engine assembly excessively. When installing the engine assembly to the hybrid vehicle transaxle assembly, make sure to securely fit the knock pins into the knock pin holes.

12. INSTALL FLYWHEEL HOUSING SIDE COVER

(a) Install the flywheel housing side coverto the engine assembly.

13. INSTALL STARTER HOLE INSULATOR

(a) Install the starter hole insulator to the engine assembly with 2 new bolts.

Torque:

46 N·m {469 kgf·cm, 34 ft·lbf}

14. CONNECT HV AIR CONDITIONING WIRE

(a) Engage the guide to connect the HV air conditioning wire to the hybrid vehicle transaxle assembly.

(b) Install the bolt.

Torque:

12.5 N·m {127 kgf·cm, 9 ft·lbf}

15. CONNECT ENGINE WIRE

(a) Engage the 2 clamps to connect the engine wire to the hybrid vehicle transaxle assembly.

(b) Install the 2 bolts.

Torque:

Bolt (A) :

8.0 N·m {82 kgf·cm, 71 in·lbf}

Bolt (B) :

12 N·m {122 kgf·cm, 9 ft·lbf}

(c) Confirm that no foreign matter or water has entered the connector of the shift lever position sensor and connect the connector.

(d) Connect the motor temperature sensor and generator temperature sensor connector.

(e) Connect the motor resolver, generator resolver and transmission fluid temperature sensor connector.

16. REMOVE ENGINE HANGERS

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17. INSTALL WIRE HARNESS CLAMP BRACKET

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18. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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19. PERFORM RESOLVER LEARNING

NOTICE:

If the hybrid vehicle transaxle assembly has been replaced, make sure to perform resolver learning.

Click here