Part 3
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ENGINE ASSEMBLY - HYBRID
Part 3
Continued From Part 2 Part 2
76. Install the Crankshaft TDC Timing Peg.
NOTE:Only turn the engine in the normal direction of rotation.
77. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
CAUTION:Only hand-tighten the bolt or damage to the front cover can occur.
78. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
- If it is not possible to install the bolt, the engine valve timing must be corrected.
79. Install the special tool to check the position of the camshafts.
- If it is not possible to install the special tool, the engine valve timing must be corrected.
80. Remove the special tool.
81. Install a new crankshaft position (CKP) sensor and the 2 bolts.
- Do not tighten the bolts at this time.
82. Adjust the CKP sensor with the alignment tool.
- Tighten the 2 CKP bolts to 7 Nm {0.7 kgf-m, 62 in-lbf}.
83. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
84. Remove the special tool.
85. Install the engine plug bolt.
- Tighten to 20 Nm {2.0 kgf-m, 177 in-lbf}.
CAUTION:Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths.
86. Clean the valve cover gasket surface with metal surface cleaner.
87. Apply silicone gasket and sealant to the locations shown.
NOTE:The valve cover must be secured within 4 minutes of silicone gasket application. If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
88. Install the valve cover.
- Tighten the bolts in the sequence shown to 10 Nm {1.0 kgf-m, 89 in-lbf}.
NOTE:Make sure the notch on the oil level indicator is aligned with the V-shaped boss on the valve cover and fully engaged into the valve cover.
89. Install the oil level indicator.
CAUTION:Only use hand tools when removing or installing the spark plugs or damage may occur to the cylinder head or spark plug.
90. Install a new cylinder head temperature (CHT) sensor and the spark plugs.
- Tighten the CHT sensor to 12 Nm {1.2 kgf-m, 106 in-lbf}.
- Tighten the spark plugs to 12 Nm {1.2 kgf-m, 106 in-lbf}.
NOTE:Apply dielectric compound to the inside of the coil-on-plug boots.
91. Install the coil-on-plugs, bolts and the crankcase vent tube.
- Tighten to 8 Nm {0.8 kgf-m, 71 in-lbf}.
92. Install the engine cover studs.
93. Install the crankshaft vent tube.
94. If equipped, install the block heater.
- Tighten to 21 Nm {2.1 kgf-m, 15 ft-lbf}.
NOTE:Spin-on type oil filter adapter shown, element-filter type similar.
NOTE:Clean the gasket mating surfaces with metal surface cleaner.
95. Install the oil filter adapter with a new gasket.
- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.
96. Install the crankcase vent oil separator and the 8 bolts.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
NOTE:The KS must not touch the crankcase vent oil separator.
97. Install the Knock Sensor (KS) and the bolt.
- Tighten to 20 Nm {2.0 kgf-m, 177 in-lbf}.
98. Install the vacuum pump assembly, the nut and the 2 bolts.
- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.
99. Install the coolant hose.
100. Install the coolant hose.
101. Install the thermostat housing.
- Tighten to 10 Nm {10 kgf-m, 89 in-lbf}.
102. Connect the EGR coolant hose and the heater hose.
103. Install the coolant hose.
CAUTION:Make sure the coolant pump is correctly seated to the engine block before installing and tightening the fasteners, or damage to the coolant pump may occur.
NOTE:Clean the coolant pump mating surface with metal surface cleaner.
NOTE:Lubricate the coolant pump O-ring with clean engine coolant.
104. Install the new O-ring, coolant pump and the 3 bolts.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
105. Install the coolant pump pulley and bolts.
- Tighten to 20 Nm {2.0 kgf-m, 177 in-lbf}.
106. Position the engine control wiring harness on the engine.
107. Attach the wiring harness retainer to the valve cover stud.
- Connect the EGR valve electrical connector.
108. Connect the CHT sensor and install the rubber boot.
109. Connect the 4 coil-on-plug electrical connectors.
CAUTION:Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-rings can cause the fuel system to leak. Do not reuse the O-ring seals.
110. Install new fuel injector O-rings.
- Separate the fuel injectors from the fuel rail.
- Remove and discard the fuel injector O-rings.
- Install new O-rings and lubricate with clean engine oil.
- Install the fuel injectors onto the fuel rail.
111. Install the fuel rail with the fuel injectors and stud bolts.
- Tighten to 23 Nm {2.3 kgf-m, 17 ft-lbf}.
112. Install the radio capacitor and nut.
- Tighten to 10 Nm {1.0 kgf-m, 89 in-lbf}.
113. Install the fuel rail insulator.
114. Position the high voltage wiring harness and attach the 2 wiring harness retainers to the ignition coil stud bolts.
115. Connect the VCT electrical connector and attach the wiring harness retainer to the valve cover stud bolt.
116. Attach the 2 wiring harness retainers to the fuel rail and the from the valve cover.
117. Connect the 4 fuel injector electrical connectors, radio capacitor electrical connector and the Camshaft Position (CMP) sensor electrical connector.
118. Install the EGR tube.
- Tighten to 55 Nm {5.6 kgf-m, 41 ft-lbf}.
119. Position the intake manifold and connect the PCV hose.
NOTE:Inspect and install new intake manifold gaskets, if necessary.
NOTE:The cylinder head side of the intake manifold is showing bolt location.
120. Install the intake manifold gasket, intake manifold and 7 bolts.
- Tighten to 18 Nm {1.8 kgf-m, 159 in-lbf}.
121. Attach the 4 wire harness pin-type retainers to the intake manifold.
122. Attach the pin-type retainer to the intake manifold and connect the KS electrical connector.
123. Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.
124. Connect the Engine Oil Pressure (EOP) switch electrical connector.
125. Connect the Evaporative Emission (EVAP) canister purge valve electrical connector.
126. Connect the electronic throttle control electrical connector.
127. Install the accessory drive belt tensioner.
- Tighten to 25 Nm {2.5 kgf-m, 18 ft-lbf}.
128. Install 7 new exhaust manifold studs in the cylinder head.
- Tighten to 17 Nm {1.7 kgf-m, 150 in-lbf}.
129. Install the new exhaust manifold gasket on the engine.
CAUTION:Failure to tighten the catalytic converter nuts to specification before installing the converter bracket bolts will cause the converter to develop an exhaust leak.
NOTE:Failure to tighten the catalytic converter nuts to specification a second time will cause the converter to develop an exhaust leak.
130. Position the catalytic converter and tighten the 7 new exhaust manifold nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 48 Nm {4.9 kgf-m, 35 ft-lbf}.
- Stage 2: Tighten to 48 Nm {4.9 kgf-m, 35 ft-lbf}.
131. Attach the 2 wiring harness pin-type retainers.
132. Install the engine wiring harness connector bracket.
- Tighten to 15 Nm {1.5 kgf-m, 133 in-lbf}.
133. Connect the Crankshaft Position (CKP) sensor electrical connector.
134. Connect the Catalyst Monitor Sensor (CMS) electrical connector.
135. Connect the Heated Oxygen Sensor (HO2S) connector. Attach the connector to the engine wiring harness connector bracket.
136. Using the Heavy Duty Floor Crane and the Spreader Bar, remove the engine from the engine stand.
NOTE:Special bolts are used for installation. Do not use standard bolts.
137. Install the flexplate and the bolts. Tighten the bolts in the sequence shown in 3 stages.
- Stage 1: Tighten to 50 Nm {5.1 kgf-m, 37 ft-lbf}.
- Stage 2: Tighten to 80 Nm {8.2 kgf-m, 59 ft-lbf}.
- Stage 3: Tighten to 112 Nm {11.4 kgf-m, 83 ft-lbf}.