Installation

3MZ-FE 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 3 bolts and rear engine mounting bracket.

Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

4. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY Installation

5. INSTALL FRONT ENGINE MOUNTING BRACKET Installation

6. INSTALL FLYWHEEL HOUSING UNDER COVER Installation

7. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

8. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

9. TEMPORARILY TIGHTEN ENGINE MOUNTING INSULATOR LH

(a) Temporarily install the engine mounting insulator LH with the 3 nuts.

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

10. TEMPORARILY TIGHTEN ENGINE MOUNTING INSULATOR RH

(a) Temporarily install the engine mounting insulator RH with the 3 nuts.

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

11. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR

(a) Temporarily install the front engine mounting insulator with the 3 nuts.

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

12. 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 front engine mounting insulator with the nut.

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

13. FULLY TIGHTEN ENGINE MOUNTING INSULATOR LH

(a) Install the engine mounting insulator LH by tightening the 3 nuts.

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

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

14. FULLY TIGHTEN ENGINE MOUNTING INSULATOR RH

(a) Install the engine mounting insulator RH by tightening the 3 nuts.

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

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

15. FULLY TIGHTEN FRONT ENGINE MOUNTING INSULATOR

(a) Install the front engine mounting insulator by tightening the 3 nuts.

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

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

16. INSTALL REAR ENGINE MOUNTING INSULATOR

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

Bolt A - Torque : 130 Nm (1326 kgf-cm, 96 ft-lbf)

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

17. INSTALL ENGINE MOUNTING ABSORBER SUB-ASSEMBLY

(a) Install the engine mounting absorber sub-assembly with the 2 bolts and 2 nuts.

Bolt - Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

Nut - Torque : 24 Nm (245 kgf-cm, 18 ft-lbf)

18. INSTALL HYBRID TRANSAXLE MASS DAMPER

(a) Install the bolt and transaxle mass damper.

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

19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

20. INSTALL MANIFOLD STAY Installation

21. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation

22. INSTALL ENGINE WIRE

23. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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

(b) Install the engine assembly to the vehicle.

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

Bolt A - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

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

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

(d) Install the front suspension member brace RH and LH with the 6 bolts and 2 nuts.

Bolt A - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

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

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

24. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY Installation

25. INSTALL FRONT AXLE ASSEMBLY LH Installation

26. INSTALL FRONT AXLE ASSEMBLY RH

HINT
Perform the same procedure as above on the opposite side.

27. INSTALL FRONT LOWER SUSPENSION ARM LH Installation

28. INSTALL FRONT LOWER SUSPENSION ARM RH

HINT
Perform the same procedure as above on the opposite side.

29. CONNECT TIE ROD END SUB-ASSEMBLY LH Installation

30. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT
Perform the same procedure as above on the opposite side.

31. INSTALL FRONT SPEED SENSOR LH Installation

32. INSTALL FRONT SPEED SENSOR RH

HINT
Perform the same procedure as above on the opposite side.

33. INSTALL FRONT AXLE SHAFT NUT LH Installation

34. INSTALL FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as above on the opposite side.

35. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

36. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as above on the opposite side.

37. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY

(a) 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.

(b) Install a new gasket to the front No. 3 exhaust pipe as shown in the illustration.

Bolt - Torque : 48 Nm (490 kgf-cm, 35 ft-lbf)

Nut - Torque : 56 Nm (571 kgf-cm, 41 ft-lbf)

(d) Connect the heated oxygen sensor connector.

38. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(a) Install 2 new gaskets and the front No. 3 exhaust pipe with the 2 bolts and 2 new nuts.

Torque : 56 Nm (571 kgf-cm, 41 ft-lbf)

(b) Connect the heated oxygen sensor connector.

39. CONNECT ENGINE WIRE

(a) Connect the connector and clamp.

(b) Install the ground cable and clamp.

Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)

(c) Install the clamp and wire harness protector.

(d) Install the 2 nuts and pull in the engine wire harness.

Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)

(e) Connect the 6 connectors to the ECM.

(f) Connect the 2 connectors.

40. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY Installation

41. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation

42. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH Installation

43. INSTALL FRONT DOOR SCUFF PLATE RH Installation

44. CONNECT WATER HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to connect the water inlet hose.

(b) Using pliers, grip the claws of the clip and slide the clip to connect the water inlet hose.

45. CONNECT INLET OIL COOLER TUBE SUB-ASSEMBLY

(a) Using pliers, grip the claws of the clip and slide the clip to connect the inlet oil cooler tube.

46. CONNECT OUTLET OIL COOLER TUBE SUB-ASSEMBLY

HINT
Connect the outlet oil cooler tube using the same procedure as for the inlet oil cooler tube.

47. CONNECT INLET RADIATOR HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to connect the inlet radiator hose.

48. CONNECT OUTLET RADIATOR HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to connect the outlet radiator hose.

49. CONNECT INLET HEATER WATER HOSE

(a) Using pliers, grip the claws of the clip and slide the clip to connect the inlet heater water hose.

50. CONNECT OUTLET HEATER WATER HOSE

HINT
Connect the outlet heater water hose using the same procedure as for the inlet heater water hose.

51. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) 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.

(b) Install the EFI fuel pipe clamp.

52. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Install the control cable to the transaxle with the bolt.

(b) Install the control shaft lever with the nut.

Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)

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

53. INSTALL NO. 1 INVERTER BRACKET

(a) Install the 4 bolts and No. 1 inverter bracket.

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

(b) Install the harness clamp and hose clamp.

54. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

(a) Temporarily install the compressor with motor assembly with the 3 bolts.

(b) Install the compressor with motor assembly by tightening the 3 bolts in the order shown in the illustration.

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

(c) Connect the 2 connectors.

55. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH

56. INSTALL ENGINE MOUNTING CONTROL BRACKET

(a) Install the 3 bolts and engine mounting control bracket.

Bolt A - Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

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

57. INSTALL ENGINE MOVING CONTROL ROD

(a) Install the 2 bolts and engine moving control rod.

Bolt A - Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

Bolt B - Torque : 56 Nm (571 kgf-cm, 41 ft-lbf)

HINT
First tighten bolt A.

58. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the 2 bolts and No. 2 engine mounting stay RH.

Torque : 64 Nm (653 kgf-cm, 47 ft-lbf)

59. INSTALL AIR CLEANER BRACKET

(a) Install the 2 bolts and air cleaner bracket.

Torque : 27 Nm (275 kgf-cm, 20 ft-lbf)

60. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

(a) Install the 2 nuts and brake master cylinder reservoir.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

(b) Connect the connector.

61. INSTALL INVERTER WITH CONVERTER ASSEMBLY Installation

62. INSTALL NO. 4 INVERTER BRACKET Installation

63. INSTALL ENGINE ROOM RELAY BLOCK ASSEMBLY Installation

64. REMOVE INVERTER COVER Installation

65. CONNECT NO. 3 FRAME WIRE Installation

66. CONNECT MG ECU CONNECTOR Installation

67. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR Installation

68. CONNECT NO. 4 ENGINE WIRE Installation

69. CHECK HIGH VOLTAGE CABLE CONNECTION Installation

70. INSTALL INVERTER COVER Installation

71. CONNECT WATER HOSE Installation

72. INSTALL INVERTER RESERVE TANK SUB-ASSEMBLY Installation

73. CONNECT NO. 2 ENGINE ROOM WIRE Installation

74. CONNECT NO. 1 CIRCUIT BREAKER SENSOR Installation

75. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation

76. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

(a) Install the air cleaner filter element to the air cleaner case.

(b) Install the 2 bolts, 4 clamps and air cleaner cap sub-assembly.

Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

77. INSTALL BATTERY CARRIER SUB-ASSEMBLY

(a) Install the 5 bolts and battery carrier.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

78. INSTALL SERVICE PLUG GRIP Installation

79. INSTALL BATTERY

(a) Install the battery clamp and battery.

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

(b) Connect the cable to the battery terminal.

Torque : 6.4 Nm (65 kgf-cm, 56 in-lbf)

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

80. INSTALL FRONT WHEELS

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

81. ADD AND INSPECT HYBRID TRANSAXLE FLUID P310 Hybrid Transaxle

82. ADD ENGINE OIL

83. INSPECT FOR FUEL LEAK Testing and Inspection

84. ADD COOLANT (for Inverter) Service and Repair

85. ADD COOLANT (for Engine) Service and Repair

86. INSPECT FOR OIL LEAK

87. INSPECT FOR COOLANT LEAKS (for Inverter) Testing and Inspection

88. INSPECT FOR COOLANT LEAKS (for Engine) Testing and Inspection

89. INSPECT FOR EXHAUST GAS LEAK Installation

90. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

HINT
Service and Repair.

91. INSTALL NO. 2 ENGINE UNDER COVER

(a) Install the 2 bolts and No. 2 engine under cover.

92. INSTALL FRONT FENDER APRON SEAL LH

(a) Install the 2 bolts, clip and fender apron seal LH.

93. INSTALL FRONT FENDER APRON SEAL RH

HINT
Perform the same procedure as above on the opposite side.

94. INSTALL FRONT FENDER LINER LH

(a) Install the front fender liner with the screw and clip.

95. INSTALL FRONT FENDER LINER RH

HINT
Perform the same procedure as above on the opposite side.

96. INSTALL NO. 1 ENGINE UNDER COVER

(a) Install the 6 bolts, 2 screws, 2 clips and No. 1 engine under cover.

97. INSPECT STEERING WHEEL CENTER POINT

98. INSPECT IGNITION TIMING Engine

99. INSPECT ENGINE IDLE SPEED Engine

100. INSPECT CO/HC Engine

101. CHECK ABS SPEED SENSOR SIGNAL

HINT
Test Mode Procedure.

102. INSTALL NO. 2 ENGINE ROOM SIDE COVER LH

(a) Fit the clips and install the No. 2 engine room side cover LH.

NOTICE:
* Be sure to engage the clips securely.
* Do not apply excessive force or do not hit the cover to engage the clips. This may cause the cover to break.
103. INSTALL COOL AIR INTAKE DUCT SEAL

(a) Install the cool air intake duct seal with the 11 clips.

104. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

105. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

106. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

107. INSTALL HOOD TO COWL TOP SEAL Installation

108. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

109. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation