RM38T0EC _51 Engine / Hybrid System _144958 M20F-FXS, M20G-FXS ENGINE MECHANICAL _0604262 ENGINE ASSEMBLY A

M20F-FXS, M20G-FXS ENGINE MECHANICAL  ENGINE ASSEMBLY  INSTALLATION  


CAUTION / NOTICE / HINT

CAUTION:

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


NOTICE:

This procedure includes the removal of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION


HINT:

Perform "Inspection After Repair" after replacing the engine assembly.

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION


CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)
A545655N01
6.271,0.521 7.021,0.688 0.75,0.167 5.427,1.219 6.177,1.385 0.75,0.167 4.688,2.573 5.438,2.74 0.75,0.167 0.052,3.406 0.802,3.573 0.75,0.167 2.667,5.583 3.333,5.75 0.667,0.167 1.167,0.031 1.917,0.198 0.75,0.167 1.125,0.333 1.875,0.5 0.75,0.167 1.083,0.292 1.917,0.542 0.833,0.25 1.135,0.677 1.885,0.844 0.75,0.167 5.042,0.25 5.792,0.417 0.75,0.167 5.385,1.448 6.135,1.615 0.75,0.167 2.854,4.365 3.771,4.531 0.917,0.167 3.74,4.719 4.49,4.885 0.75,0.167 1.063,3.719 1.813,3.885 0.75,0.167 6.333,3.885 7.083,4.052 0.75,0.167 3.875,5.031 4.625,5.198 0.75,0.167 4.5,5.51 5.25,5.677 0.75,0.167 1.104,1.063 1.854,1.229 0.75,0.167 0.833,4.667 1.833,4.833 1,0.167 0.667,4.417 1.333,4.583 0.667,0.167 0.833,5.583 1.5,5.75 0.667,0.167 0.083,4.25 2.083,5.781 2,1.531 2.083,4.698 3.5,5.781 1.417,1.083 6.531,0.229 6.865,0.229 false 3.865,3.563 4.052,3.208 4.052,3.208 4.219,3.208 false 4.813,4.031 4.979,3.729 4.979,3.729 5.146,3.729 false 0.833,4.75 0.667,4.75 0.667,4.75 0.5,5.188 false 1.448,1.531 1.615,1.531 1.615,1.531 1.927,1.938 false 0.802,2.354 0.969,2.354 0.969,2.354 1.188,2.583 false 3.813,0.313 4.146,0.313 false 6.438,1.083 6.354,1.292 6.354,1.292 6.188,1.292 false 6.031,1.052 6.104,0.865 6.104,0.865 6.271,0.865 false 5.104,2.063 5.292,1.885 5.292,1.885 5.458,1.885 false 5.75,2.365 5.625,2.646 5.625,2.646 5.458,2.646 false 3.083,4 3.083,3.854 3.083,3.854 3.188,3.656 false 0.438,3.396 0.438,3.229 0.438,3.229 0.5,3.031 false 2.417,5.5 2.5,5.667 2.5,5.667 2.667,5.667 false 3.104,0.208 3.104,0.104 3.104,0.104 1.917,0.104 false 1.885,0.417 2.396,0.417 false 2.479,0.177 2.177,0.177 2.177,0.177 2.177,0.417 false 1.896,0.75 2.063,0.75 2.063,0.75 2.438,0.677 false 5.958,0.76 6.094,0.594 6.094,0.594 6.26,0.594 false 4.667,0.979 4.865,0.333 4.865,0.333 5.031,0.333 false 5.021,1.25 5.208,1.521 5.208,1.521 5.375,1.521 false 3.781,4.438 3.948,4.438 3.948,4.438 4.229,4.073 false 4.5,4.813 4.667,4.813 4.667,4.813 5.156,4.26 false 1.813,3.802 2.146,3.802 false 6.177,3.969 6.333,3.969 false 4.635,5.115 4.969,5.115 false 5.26,5.583 5.427,5.583 5.427,5.583 5.917,5.688 false 1.865,1.135 2.031,1.135 2.031,1.135 2.385,1.552 false 0.667,4.5 0.5,4.5 0.5,4.5 0.25,5.167 false 1.49,5.083 1.656,5.083 false 2.667,5.083 2.917,5.083 false 0.583,5.5 0.667,5.667 0.667,5.667 0.833,5.667 false 4.208,0.125 4.625,0.448 0.417,0.323 18 false 10 6.333,0.708 6.75,1.031 0.417,0.323 18 false 9 1.24,1.406 1.656,1.729 0.417,0.323 18 false 8 1.875,4.927 2.302,5.25 0.427,0.323 18 false 6 4.552,3.073 4.969,3.396 0.417,0.323 18 false 4 5.5,3.625 5.917,3.948 0.417,0.323 18 false 5 6.354,0.083 6.771,0.406 0.417,0.323 18 false 2 2.615,4.333 2.927,4.531 0.313,0.198 10 false ●★ 2.5,5.469 2.813,5.667 0.313,0.198 10 false x4 5.854,2.25 6.167,2.448 0.313,0.198 10 false x2 0.573,2.25 0.99,2.573 0.417,0.323 18 false 1 6.354,0.531 7.094,0.792 0.74,0.26 8 false 43 (438, 32) 5.479,1.229 6.313,1.469 0.833,0.24 8 false 43 (438, 32) 5.76,1.74 6.177,2.063 0.417,0.323 18 false 1 3.125,4 3.542,4.323 0.417,0.323 18 false 3 4.771,2.583 5.604,2.823 0.833,0.24 8 false 43 (438, 32) 0.104,3.406 0.938,3.646 0.833,0.24 8 false 43 (438, 32) 2.698,5.583 3.531,5.75 0.833,0.167 8 false 25 (255, 18) 1.26,0.031 2.094,0.271 0.833,0.24 8 false 10 (102, 7) 1.24,0.344 2.073,0.583 0.833,0.24 8 false 10 (102, 7) 3.188,0.115 3.5,0.313 0.313,0.198 10 false x2 1.25,0.688 2.083,0.927 0.833,0.24 8 false 10 (102, 7) 5.135,0.26 5.969,0.5 0.833,0.24 8 false 10 (102, 7) 5.479,1.458 6.313,1.698 0.833,0.24 8 false 20 (204, 15) 5.115,1.104 5.427,1.302 0.313,0.198 10 false x2 2.552,0.302 2.865,0.5 0.313,0.198 10 false x2 4.958,5.167 5.271,5.365 0.313,0.198 10 false x2 5.083,4.333 5.396,4.531 0.313,0.198 10 false x6 4.219,4.135 4.531,4.333 0.313,0.198 10 false x8 2.219,3.875 2.531,4.073 0.313,0.198 10 false x4 2.917,4.365 3.75,4.604 0.833,0.24 8 false 150 (1530, 111) 3.802,4.729 4.635,4.969 0.833,0.24 8 false 30 (306, 22) 1.125,3.719 1.958,3.958 0.833,0.24 8 false 46 (469, 34) 6.406,3.885 7.063,4.156 0.656,0.271 8 false 46 (469, 34) 3.948,5.042 4.604,5.313 0.656,0.271 8 false 64 (653, 47) 4.573,5.51 5.229,5.781 0.656,0.271 8 false 25 (255, 18) 3.604,4.698 3.917,4.896 0.313,0.198 10 false ● 1.177,1.073 2.01,1.313 0.833,0.24 8 false 20 (204, 15) 2.521,4.927 2.948,5.25 0.427,0.323 18 false 7 0.865,5.583 1.698,5.75 0.833,0.167 8 false 25 (255, 18) 0.854,4.667 1.854,4.833 1,0.167 8 false 9.8 (100, 87 in.*lbf) 0.688,4.417 1.521,4.583 0.833,0.167 8 false 25 (255, 18) 0.667,5.469 0.979,5.667 0.313,0.198 10 false x2 0.75,5.198 1.063,5.396 0.313,0.198 10 false x2 0.188,5.208 0.5,5.406 0.313,0.198 10 false x2 0.125,4.271 0.438,4.469 0.313,0.198 12 false *A 2.104,4.719 2.417,4.917 0.313,0.198 12 false *B

Procedure Part Name Code
Z101186

Z101188

Z101187

1 INSTALL ENGINE HANGERS - (Click here) - -
2 ENGINE FROM ENGINE STAND - (Click here) - -
3 NO. 1 CRANKSHAFT POSITION SENSOR PLATE 19315 (Click here) - -
4 FLYWHEEL SUB-ASSEMBLY 13405 (Click here) - -
5 TRANSMISSION INPUT DAMPER ASSEMBLY 31270 (Click here) - -
6 COMPRESSOR WITH MOTOR ASSEMBLY 88370 (Click here) - -
7 COMPRESSOR WITH MOTOR ASSEMBLY 88370 (Click here) - -
8 ENGINE ASSEMBLY - (Click here) - -
9 MANIFOLD STAY 17118 - - -
10 INSTALL ENGINE WIRE 82121 - - -

*A for FTMC Made *B for GTMC Made
V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque
● Non-reusable part ★ Precoated part

A538209N04
0.167,3.271 0.917,3.438 0.75,0.167 1.219,0.167 1.969,0.333 0.75,0.167 6.333,0.656 7.083,0.823 0.75,0.167 6.083,0.896 6.833,1.063 0.75,0.167 6.313,4.073 7.063,4.24 0.75,0.167 3.052,0.719 3.802,0.885 0.75,0.167 0.854,1.115 1.604,1.281 0.75,0.167 4.594,3.167 5.344,3.333 0.75,0.167 4.667,3.698 5.417,3.865 0.75,0.167 6.177,2.24 7.146,2.406 0.969,0.167 4.531,2.031 5.281,2.198 0.75,0.167 1.25,1.969 2.375,2.135 1.125,0.167 0.813,1.073 1.646,1.323 0.833,0.25 4.49,1.99 5.323,2.24 0.833,0.25 4.625,3.656 5.458,3.906 0.833,0.25 4.552,3.125 5.385,3.375 0.833,0.25 3.01,0.677 3.844,0.927 0.833,0.25 5.531,4.333 6.448,4.5 0.917,0.167 5.49,4.292 6.49,4.542 1,0.25 5.396,4.792 6.313,4.958 0.917,0.167 5.354,4.75 6.354,5 1,0.25 4.792,5.531 5.792,5.781 1,0.25 4.833,5.573 5.75,5.74 0.917,0.167 2.917,5.583 3.667,5.75 0.75,0.167 1.938,5.104 2.688,5.271 0.75,0.167 4.75,2.531 5.583,2.781 0.833,0.25 4.792,2.573 5.542,2.74 0.75,0.167 1.156,0.583 1.323,0.583 1.323,0.583 2.406,1.24 false 1.333,2.583 1.583,2.583 false 0.563,4.333 0.938,4.333 false 1.167,3.833 1.5,3.833 false 1.927,4.979 2.094,4.979 2.094,4.979 2.26,4.563 false 3.083,5.417 3.25,5.417 3.25,5.417 3.448,5.156 false 5.5,5.25 5.833,5.25 false 4.188,2.885 4.021,2.885 4.021,2.885 3.896,3.177 false 6.313,3.583 6.563,3.583 false 4.688,1.052 5.021,1.052 false 5.302,1.656 5.688,1.656 false 5.427,0.448 5.76,0.448 false 4.031,0.229 4.198,0.229 4.198,0.229 4.313,0.76 false 1.979,0.26 2.365,0.26 false 6.719,0.656 6.719,0.49 6.719,0.49 6.542,0.417 false 5.698,0.979 6.083,0.979 false 6.125,4.156 6.313,4.156 false 2.375,2.063 2.542,2.063 2.542,2.063 2.875,1.854 false 2.823,0.813 3.052,0.813 false 1.604,1.198 1.833,1.198 false 5.354,3.24 5.521,3.24 5.521,3.24 5.635,3.031 false 5.042,3.688 5.042,3.552 5.042,3.552 5.281,3.469 false 5.281,2.125 5.448,2.125 5.448,2.125 5.917,2.333 false 6.167,2.313 6.083,2.313 6.083,2.313 6.083,2.594 false 5.063,4.875 5.396,4.875 false 5.271,4.635 5.365,4.417 5.365,4.417 5.531,4.417 false 4.302,5.281 4.667,5.656 4.667,5.656 4.833,5.656 false 3.667,5.667 3.833,5.667 3.833,5.667 3.979,5.531 false 2.688,5.188 2.854,5.188 2.854,5.188 3,5.052 false 0.917,3.354 1.083,3.354 false 5.552,2.646 5.719,2.646 5.719,2.646 6.417,3.01 true 0.292,2.813 0.385,2.594 0.385,2.594 0.552,2.594 false 2.74,5.271 3.292,5.625 0.552,0.354 18 false 21 1.594,4.802 2.146,5.156 0.552,0.354 18 false 22 4.438,2.719 4.99,3.073 0.552,0.354 18 false 20 5.885,5.115 6.438,5.469 0.552,0.354 18 false 19 5.094,0.26 5.646,0.615 0.552,0.354 18 false 18 4.365,0.896 4.917,1.25 0.552,0.354 18 false 17 5,1.479 5.552,1.833 0.552,0.354 18 false 16 6.844,3.438 7.156,3.719 0.313,0.281 18 false 15 0.813,0.438 1.365,0.792 0.552,0.354 18 false 14 0.823,3.646 1.375,4 0.552,0.354 18 false 13 0.219,4.146 0.771,4.5 0.552,0.354 18 false 12 3.698,0.052 4.25,0.406 0.552,0.354 18 false 11 3.104,4.865 3.417,5.063 0.313,0.198 10 false x4 4.083,5.375 4.396,5.573 0.313,0.198 10 false x4 4.375,5.146 4.688,5.344 0.313,0.198 10 false x2 5.083,4.875 5.396,5.073 0.313,0.198 10 false x2 5.333,4.542 5.646,4.74 0.313,0.198 10 false x2 6.563,3.01 6.875,3.208 0.313,0.198 10 false x2 6.563,1.531 6.875,1.729 0.313,0.198 10 false x2 2.51,0.281 2.823,0.479 0.313,0.198 10 false x2 6.188,2.688 6.5,2.885 0.313,0.198 10 false x2 0.229,3.271 0.938,3.469 0.708,0.198 8 false 46 (469, 34) 1.604,2.396 2.156,2.75 0.552,0.354 18 false 16 0.646,2.896 0.958,3.094 0.313,0.198 10 false x2 1.25,3.24 1.563,3.438 0.313,0.198 10 false x2 1.969,1.208 2.281,1.406 0.313,0.198 10 false x2 5.604,3.083 5.917,3.281 0.313,0.198 10 false x2 1.25,0.167 1.958,0.365 0.708,0.198 8 false 10.5 (107, 8) 6.406,0.656 7.115,0.854 0.708,0.198 8 false 43 (438, 32) 6.115,0.896 6.823,1.094 0.708,0.198 8 false 10.5 (107, 8) 6.396,4.083 7.104,4.281 0.708,0.198 8 false 20 (204, 15) 3.125,0.719 3.833,0.917 0.708,0.198 8 false 72 (734, 53) 0.938,1.125 1.646,1.323 0.708,0.198 8 false 72 (734, 53) 5.74,2.417 6.052,2.615 0.313,0.198 10 false x3 4.594,2.031 5.302,2.229 0.708,0.198 8 false 70 (714, 52) 4.75,3.708 5.458,3.906 0.708,0.198 8 false 42 (428, 31) 6.219,2.25 7.135,2.448 0.917,0.198 8 false 8.0 (82, 71 in.*lbf) 4.667,3.167 5.375,3.365 0.708,0.198 8 false 42 (428, 31) 1.302,1.958 2.667,2.125 1.365,0.167 8 false 9.8 (100, 87 in.*lbf) 5.573,4.333 6.49,4.5 0.917,0.167 8 false 141 (1438, 104) 5.448,4.792 6.365,4.958 0.917,0.167 8 false 141 (1438, 104) 4.885,5.583 5.802,5.75 0.917,0.167 8 false 141 (1438, 104) 2.979,5.583 3.688,5.781 0.708,0.198 8 false 70 (714, 52) 1.99,5.104 2.698,5.302 0.708,0.198 8 false 70 (714, 52) 4.865,2.583 5.573,2.781 0.708,0.198 8 false 42 (428, 31) 0.583,2.51 0.896,2.708 0.313,0.198 10 false *1

Procedure Part Name Code
Z101186

Z101188

Z101187

11 HIGH VOLTAGE AIR CONDITIONING WIRE 821H2A (Click here) - -
12 FLYWHEEL HOUSING SIDE COVER 11363A (Click here) - -
13 STARTER HOLE INSULATOR 28193 - - -
14 ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 12305 (Click here) - -
15 ENGINE MOUNTING INSULATOR LH 12372A (Click here) - -
16 REMOVE ENGINE HANGERS - - - -
17 WIRE HARNESS CLAMP BRACKET - - - -
18 EMISSION CONTROL VALVE BRACKET - - - -
19 DIFFERENTIAL PRESSURE SENSOR 89481B - - -
20 ENGINE ASSEMBLY WITH TRANSAXLE - (Click here) - -
21 REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH 51108A - - -
22 REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH 51107A - - -

*1 ENGINE MOUNTING BRACKET CAP - -
V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque

A545637N02
1.75,0.667 2.5,0.833 0.75,0.167 2.948,2.719 3.615,2.885 0.667,0.167 5.417,1.583 6.167,1.75 0.75,0.167 6.188,3.417 6.938,3.583 0.75,0.167 1.708,0.625 2.542,0.875 0.833,0.25 0.917,0.479 1.063,0.354 1.063,0.354 1.229,0.354 false 0.333,1.917 0.667,1.917 false 1.344,3.052 1.51,3.052 1.51,3.052 1.698,2.781 false 3.719,1.781 4.021,2.281 4.021,2.281 4.188,2.281 false 6.531,3.417 6.531,3.167 false 0.667,1.417 1,1.417 false 3.281,2.385 3.281,2.719 false 5.156,1.333 5.25,1.667 5.25,1.667 5.417,1.667 false 6.125,2.417 5.792,2.417 false 1.417,0.75 1.75,0.75 false 1.469,0.146 2.021,0.5 0.552,0.354 18 false 27 1.813,0.667 2.75,0.927 0.938,0.26 8 false 64 (653, 47) 1.063,1.229 1.615,1.583 0.552,0.354 18 false 28 0.979,1.698 1.531,2.052 0.552,0.354 18 false 26 1.021,2.875 1.573,3.229 0.552,0.354 18 false 23 2.979,2.719 3.917,2.979 0.938,0.26 8 false 43 (438, 32) 3.344,2.26 3.594,2.521 0.25,0.26 10 false x2 3.073,2.042 3.323,2.302 0.25,0.26 10 false x2 4.51,2.104 5.063,2.458 0.552,0.354 18 false 24 5.198,1.26 5.448,1.521 0.25,0.26 10 false x2 5.396,1.052 5.646,1.313 0.25,0.26 10 false x2 5.479,1.583 6.417,1.844 0.938,0.26 8 false 43 (438, 32) 5.469,2.25 6.021,2.604 0.552,0.354 18 false 25 6.667,2.49 6.917,2.75 0.25,0.26 10 false x3 6.635,3 6.885,3.26 0.25,0.26 10 false x12 6.26,3.417 7,3.677 0.74,0.26 8 false 29 (296, 21)

Procedure Part Name Code
Z101186

Z101188

Z101187

23 DRIVE SHAFT ASSEMBLY - - - -
24 FRONT EXHAUST PIPE ASSEMBLY 17410 (Click here) - -
25 FRONT FLOOR CENTER BRACE 57533B - - -
26 NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY 45025D (Click here) - -
27 NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY 45260 (Click here) - -
28 COLUMN HOLE COVER SILENCER SHEET 45259A - - -

V111893

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping": N*m (kgf*cm, ft.*lbf)
V100146

N*m (kgf*cm, ft.*lbf): Specified torque

A538215N02
0.156,2.552 1.115,2.719 0.958,0.167 6.042,3.771 6.75,3.938 0.708,0.167 6,3.729 6.792,3.979 0.792,0.25 1.635,1.26 1.802,1.01 1.802,1.01 1.969,1.01 false 0.802,1.24 0.958,1.406 0.958,1.406 1.125,1.406 false 0.667,2.313 0.833,2.313 0.833,2.313 0.948,2.156 false 0.656,3.5 0.99,3.5 false 0.708,4.604 1.135,4.604 false 1,5.302 1.333,5.302 false 2.333,5.146 2.667,5.146 false 5.396,4.667 5.479,5 5.479,5 5.646,5 false 5.844,2.854 6.177,2.854 false 5.438,3.438 5.771,3.438 false 4.583,1.667 4.417,1.667 4.417,1.667 4.417,1.917 false 5.115,0.813 5.281,0.813 5.281,0.813 5.74,1.427 false 5.594,2.125 5.677,2.458 5.677,2.458 5.844,2.458 false 5.896,0.417 6.063,0.417 6.063,0.417 6.188,0.896 false 6.771,0.375 6.938,0.375 6.938,0.375 6.938,0.958 false 0.49,1.375 0.938,1.74 0.938,1.74 1.104,1.74 false 3.01,1.385 3.219,1.667 3.219,1.667 3.385,1.667 false 0.635,0.729 0.969,0.729 false 1.115,2.635 1.365,2.635 false 0.646,2.927 0.813,2.927 0.813,2.927 1.198,3.021 false 0.698,3.927 0.865,3.927 0.865,3.927 1.042,4.042 false 6.042,3.865 5.125,3.865 5.125,3.865 5.125,4.135 false 5.427,4.042 5.427,3.865 false 4.854,1.188 5.021,1.188 5.021,1.188 5.281,1.76 false 0.656,4.323 1.083,4.323 false 0.75,5.01 0.917,5.01 0.917,5.01 1.417,4.844 false 2.208,1.354 2.542,1.354 false 0.302,0.594 0.688,0.948 0.385,0.354 18 false 48 6.229,2.708 6.615,3.063 0.385,0.354 18 false 46 5.698,4.823 6.083,5.177 0.385,0.354 18 false 45 0.292,2.781 0.677,3.135 0.385,0.354 18 false 44 3.417,1.479 3.802,1.833 0.385,0.354 18 false 43 2.708,4.979 3.094,5.333 0.385,0.354 18 false 42 0.677,5.135 1.063,5.49 0.385,0.354 18 false 41 4.76,0.625 5.146,0.979 0.385,0.354 18 false 47 5.885,2.281 6.271,2.635 0.385,0.354 18 false 39 2.01,0.833 2.396,1.188 0.385,0.354 18 false 38 1.188,1.271 1.573,1.625 0.385,0.354 18 false 37 0.333,2.125 0.719,2.479 0.385,0.354 18 false 36 1.156,1.573 1.542,1.927 0.385,0.354 18 false 35 6.417,0.208 6.802,0.563 0.385,0.354 18 false 34 5.542,0.208 5.927,0.563 0.385,0.354 18 false 33 4.781,1.5 5.167,1.854 0.385,0.354 18 false 31 0.333,3.333 0.719,3.688 0.385,0.354 18 false 32 0.344,3.76 0.729,4.115 0.385,0.354 18 false 30 0.344,4.458 0.729,4.813 0.385,0.354 18 false 29 1.448,2.583 1.76,2.781 0.313,0.198 10 false x2 5.802,3.271 6.188,3.625 0.385,0.354 18 false 45 0.177,2.542 1.177,2.74 1,0.198 8 false 5.0 (51, 44 in.*lbf) 6.094,3.76 7.094,3.958 1,0.198 8 false 10 (102, 7) 4.51,1.01 4.896,1.365 0.385,0.354 18 false 40 0.5,4.219 0.656,4.417 0.156,0.198 10 false ● 0.604,4.906 0.76,5.104 0.156,0.198 10 false ● 1.281,0.208 1.594,0.406 0.313,0.198 10 false x3 2.083,1.25 2.24,1.448 0.156,0.198 10 false ●

Procedure Part Name Code
Z101186

Z101188

Z101187

29 SUCTION HOSE SUB-ASSEMBLY 88704 (Click here) - -
30 DISCHARGE HOSE SUB-ASSEMBLY 88703 (Click here) - -
31 FUEL TUBE SUB-ASSEMBLY 23901 (Click here) - -
32 WATER BY-PASS HOSE 16283B - - -
33 OUTLET HEATER WATER HOSE - (Click here) - -
34 INLET HEATER WATER HOSE - (Click here) - -
35 PURGE VALVE (PURGE VSV) 25860 - - -
36 NO. 1 FUEL VAPOR FEED HOSE 23826 - - -
37 NO. 2 FUEL VAPOR FEED HOSE 23827A - - -
38 NO. 3 FUEL VAPOR FEED HOSE 23827F - - -
39 NO. 1 INVERTER COOLING OUTLET HOSE G922C - - -
40 INLET HYBRID RADIATOR HOSE G922H - - -
41 NO. 2 RADIATOR HOSE 16572D - - -
42 NO. 1 RADIATOR HOSE 16571C - - -
43 TRANSMISSION CONTROL CABLE ASSEMBLY 33820B - - -
44 INVERTER RESERVE TANK ASSEMBLY G910GB (Click here) - -
45 CONNECT ENGINE WIRE - - - -
46 NO. 1 RELAY BLOCK COVER 82662A - - -
47 INVERTER WITH CONVERTER ASSEMBLY G92A0 (Click here) - -
48 INLET NO. 1 AIR CLEANER 17880 - - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part
V100135

Compressor oil ND-OIL 11 or equivalent - -

A531820N03
0.365,2.052 1.365,2.219 1,0.167 1.615,0.885 1.948,0.885 false 6.479,0.188 6.813,0.188 false 6.479,0.604 6.813,0.604 false 6.354,1.969 6.542,1.969 false 2.781,1.365 3,0.917 3,0.917 3.167,0.917 false 1.365,2.146 1.698,2.146 false 4.052,1.542 4.156,1.25 4.156,1.25 4.323,1.25 false 1.99,0.719 2.542,1.073 0.552,0.354 18 false 66 1.083,0.052 1.344,0.281 0.26,0.229 10 false x5 3.219,0.75 3.771,1.104 0.552,0.354 18 false 67 4.354,1.063 4.906,1.417 0.552,0.354 18 false 65 6.802,1.875 7.156,2.229 0.354,0.354 18 false 68 4.833,1.646 5.094,1.875 0.26,0.229 10 false x5 2.573,2.375 2.865,2.615 0.292,0.24 10 false x10 1.844,2.073 2.104,2.302 0.26,0.229 10 false x4 4.719,0.021 6.552,0.396 1.833,0.375 18 false 53 - 64, 69 - 74 5.625,0.417 6.49,0.802 0.865,0.385 18 false 49 - 52 0.417,2.052 1.417,2.25 1,0.198 8 false 7.5 (76, 66 in.*lbf)

Procedure Part Name Code
Z101186

Z101188

Z101187

49 ADD ENGINE OIL - - (Click here) -
50 ADD ENGINE COOLANT - - (Click here) -
51 ADD HYBRID TRANSAXLE FLUID - - (Click here) -
52 CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT - - (Click here) -
53 WARM UP COMPRESSOR - (Click here) - -
54 INSPECT HYBRID TRANSAXLE FLUID - (Click here) - -
55 INSPECT SHIFT LEVER POSITION - (Click here) - -
56 ADJUST SHIFT LEVER POSITION - (Click here) - -
57 INSPECT FOR ENGINE OIL LEAK - (Click here) - -
58 INSPECT FOR COOLANT LEAK - (Click here) - -
59 INSPECT FOR COOLANT LEAK - (Click here) - -
60 INSPECT FOR REFRIGERANT LEAK - (Click here) - -
61 INSPECT FOR FUEL LEAK - (Click here) - -
62 INSPECT FOR EXHAUST GAS LEAK - (Click here) - -
63 CHECK ENGINE OIL LEVEL - (Click here) - -
64 INSPECT ENGINE COOLANT LEVEL IN RESERVOIR (for Engine) - (Click here) - -
65 REAR ENGINE UNDER COVER LH 51444A - - -
66 REAR ENGINE UNDER COVER RH 51443C - - -
67 NO. 1 ENGINE UNDER COVER ASSEMBLY 51410 - - -
68 FRONT WHEELS - (Click here) - -
69 ALIGN FRONT WHEELS FACING STRAIGHT AHEAD - (Click here) - -
70 INSPECT AND ADJUST FRONT WHEEL ALIGNMENT - (Click here) - -
71 INSPECT IGNITION TIMING - (Click here) - -
72 INSPECT ENGINE IDLE SPEED - (Click here) - -
73 INSPECT CO/HC - (Click here) - -
74 CHECK SPEED SENSOR SIGNAL - (Click here) - -

V100146

N*m (kgf*cm, ft.*lbf): Specified torque - -

PROCEDURE

Hide 2.REMOVE ENGINE FROM ENGINE STAND

a.

Remove the engine assembly from the engine stand.


Hide 19315 3.INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

Z101186

Click here(Click here)

Hide 13405 4.INSTALL FLYWHEEL SUB-ASSEMBLY

Z101186

Click here(Click here)

Hide 31270 5.INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY

Z101186

Click here(Click here)

Hide 88370 6.INSTALL COMPRESSOR WITH MOTOR ASSEMBLY (for FTMC Made)

Z101186

Click here(Click here)

Hide 88370 7.INSTALL COMPRESSOR WITH MOTOR ASSEMBLY (for GTMC Made)

Z101186

Click here(Click here)

Hide 8.INSTALL ENGINE ASSEMBLY

Z101186

Click here(Click here)

Hide 82121 10.INSTALL ENGINE WIRE

a.
A528157

HINT:

The illustrations are representative examples, and details may differ.



b.
A528158N01
2.208,0.229 2.365,0.427 0.156,0.198 10 true A 2.521,0.708 2.677,0.906 0.156,0.198 10 true A 2.25,1.083 2.406,1.281 0.156,0.198 10 true A 4.281,0.198 4.438,0.396 0.156,0.198 10 true A 4.979,0.896 5.135,1.094 0.156,0.198 10 true A 5.469,0.927 5.625,1.125 0.156,0.198 10 true A 6.021,2.99 6.177,3.188 0.156,0.198 10 true A 1.531,3.719 1.688,3.917 0.156,0.198 10 true B 4.042,4.448 4.198,4.646 0.156,0.198 10 true B 4.052,5.083 4.208,5.281 0.156,0.198 10 true B

Torque:
Bolt (A) : 10 N*m (102 kgf*cm, 7 ft.*lbf)
Bolt (B) : 20 N*m (204 kgf*cm, 15 ft.*lbf)


Hide 821H2A 11.CONNECT HIGH VOLTAGE AIR CONDITIONING WIRE

a.
A528159C03
1.271,0.875 1.531,0.656 true 0.729,0.448 1.01,0.802 0.281,0.354 18 false i 3.729,0.49 4.01,0.844 0.281,0.354 18 false ii 1.563,0.531 1.875,0.729 0.313,0.198 10 false *a
*a Green-colored Lock - -
V100137

Slide - -


i.

Connect the connector and slide the green-colored lock as shown in the illustration to lock it securely.

CAUTION:

Make sure to wear insulated gloves.


NOTICE:

Make sure that the connector is connected securely.



ii.

Engage the 2 clamps to connect the HV air conditioning wire to the hybrid vehicle transaxle assembly.



Hide 11363A 12.INSTALL FLYWHEEL HOUSING SIDE COVER

Hide 12305 14.INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

Z101186

HINT:

Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.



a.
A538217N01
0.406,0.458 1.125,0.729 0.719,0.271 18 true i, ii, iii 3.875,0.5 4.146,0.802 0.271,0.302 18 false iv 1.073,2.344 1.24,2.521 0.167,0.177 10 true A 3.042,1.802 3.208,1.979 0.167,0.177 10 true B 1.854,0.76 2.021,0.938 0.167,0.177 10 true C

i.

Temporarily install the engine mounting insulator sub-assembly RH to the vehicle.


ii.

Install the 2 bolts and nut in the order shown in the illustration.

Torque:
72 N*m (734 kgf*cm, 53 ft.*lbf)

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 2 bolts and nut in the order of (B), (A) and (C).



iii.

Connect the air conditioner tube and accessory assembly with the nut.

Torque:
9.8 N*m (100 kgf*cm, 87 in.*lbf)


iv.

Install the No. 2 earth wire to the engine mounting insulator sub-assembly RH and vehicle with the 2 bolts.

Torque:
10.5 N*m (107 kgf*cm, 8 ft.*lbf)



Hide 12372A 15.INSTALL ENGINE MOUNTING INSULATOR LH

Z101186

HINT:

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



a.
A538218N01
0.333,0.042 0.729,0.323 0.396,0.281 18 true i, ii 2.448,0.094 2.625,0.281 0.177,0.188 10 true E 0.802,0.917 0.979,1.104 0.177,0.188 10 true A 0.927,1.5 1.104,1.688 0.177,0.188 10 true C 2.76,0.865 2.938,1.052 0.177,0.188 10 true D 2.99,1.417 3.167,1.604 0.177,0.188 10 true B 3.833,0.052 4.146,0.365 0.313,0.313 18 false iii

i.

Temporarily install the engine mounting insulator LH to the vehicle.


ii.

Install the 4 bolts and nut in the order shown in the illustration.

Torque:
42 N*m (428 kgf*cm, 31 ft.*lbf)

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 4 bolts and nut in the order of (B), (C), (D), (A) and (E).



iii.

Engage the 2 clamps and connect the connector.



Hide 18.INSTALL EMISSION CONTROL VALVE BRACKET

Torque:
43 N*m (438 kgf*cm, 32 ft.*lbf)

Hide 20.INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

a.
A528163N02
0.76,0.146 1.042,0.5 0.281,0.354 18 false i 3.854,0.063 4.135,0.417 0.281,0.354 18 false ii 0.292,1.969 0.573,2.323 0.281,0.354 18 false iii 3.833,2.031 4.115,2.385 0.281,0.354 18 false iv 0.313,4.01 0.594,4.365 0.281,0.354 18 false v 6.156,3.021 6.344,3.219 0.188,0.198 10 true A 5.719,2.531 5.906,2.729 0.188,0.198 10 true B 4.979,2.042 5.167,2.24 0.188,0.198 10 true C 4.792,2.76 4.958,2.938 0.167,0.177 10 true D 4.313,2.333 4.5,2.531 0.188,0.198 10 true E

i.

Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front suspension crossmember sub-assembly level, set an engine lifter underneath the engine assembly with transaxle and front suspension crossmember subassembly.

NOTICE:
·

Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle horizontal.

·

Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury.

However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

·

To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.




ii.

Operate the engine lifter and install the engine assembly with transaxle to the vehicle.

CAUTION:

Do not raise the engine assembly with transaxle more than necessary. If the engine assembly with transaxle is raised excessively, the vehicle may also be lifted up.


NOTICE:
·

Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

·

While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.




iii.

Connect the front suspension crossmember sub-assembly to the vehicle with the 6 bolts.

Torque:
141 N*m (1438 kgf*cm, 104 ft.*lbf)


iv.

Install the engine mounting insulator LH to the engine mounting bracket LH with the through 5 bolts and nut in the order shown in the illustration.

Torque:
Bolt (A), (B), (C) : 70 N*m (714 kgf*cm, 52 ft.*lbf)
Bolt (D), (E) : 8.0 N*m (82 kgf*cm, 71 in.*lbf)
Nut : 20 N*m (204 kgf*cm, 15 ft.*lbf)

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the 5 bolts and nut in the order of (D), (E), (A), (B) and (C).



v.

Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 2 bolts and nut.

Torque:
Bolt : 72 N*m (734 kgf*cm, 53 ft.*lbf)
Nut : 41 N*m (418 kgf*cm, 30 ft.*lbf)



Hide 51107A 22.INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

a.

Use the same procedure as for the LH side.


Hide 17410 24.INSTALL FRONT EXHAUST PIPE ASSEMBLY

Z101186

Click here(Click here)

Hide 45025D 26.CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

Z101186

Click here(Click here)

Hide 45260 27.CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Z101186

Click here(Click here)

Hide 88704 29.CONNECT SUCTION HOSE SUB-ASSEMBLY

Z101186

Click here(Click here)

Hide 88703 30.CONNECT DISCHARGE HOSE SUB-ASSEMBLY

Z101186

Click here(Click here)

Hide 23901 31.CONNECT FUEL TUBE SUB-ASSEMBLY

a.
A528164N01
0.354,0.031 0.635,0.385 0.281,0.354 18 false i 3.781,0.052 4.063,0.406 0.281,0.354 18 false ii

i.

Connect the fuel tube sub-assembly to the fuel pipe.

Click hereEngine / Hybrid System>M20F-FXS, M20G-FXS (FUEL)>FUEL SYSTEM>PRECAUTION


ii.

Engage the claw and install the No. 1 fuel pipe clamp as shown in the illustration.



Hide 16283B 32.CONNECT WATER BY-PASS HOSE

Hide 33.CONNECT OUTLET HEATER WATER HOSE

a.
A528165C02
1.771,0.948 2.552,0.323 2.552,0.323 2.198,0.865 true 1.854,1.219 2.677,1.417 2.677,1.417 2.281,1.135 true 5.208,0.5 5.5,0.292 true 0.323,0.01 0.604,0.365 0.281,0.354 18 false i 3.469,0.031 4,0.344 0.531,0.313 18 false ii, iii 2.604,0.167 2.802,0.375 0.198,0.208 10 false *a 2.719,1.323 2.917,1.531 0.198,0.208 10 false *b 5.563,0.167 5.76,0.375 0.198,0.208 10 true *c
*a Protrusion *b Cutout
*c Retainer - -
V100135

Push
V100136

Push in


i.

Align the protrusions of the outlet heater water hose connector with the cutouts in the water hose sub-assembly and push them together until the outlet heater water hose connector makes a "click" sound.


ii.

Push in the retainer.


iii.

Check that the water hose sub-assembly and outlet heater water hose connector are securely connected by pulling on them.



Hide 34.CONNECT INLET HEATER WATER HOSE

a.
A528166C02
1.323,0.531 1.813,0.635 true 1.385,0.802 1.875,0.906 true 5.667,0.698 6.083,0.563 true 1.469,0.031 1.75,0.385 0.281,0.354 18 false i 3.458,0.052 3.938,0.323 0.479,0.271 18 false ii, iii 1.198,0.677 1.51,0.875 0.313,0.198 10 false *a 1.146,0.427 1.458,0.625 0.313,0.198 10 false *b 6.135,0.448 6.333,0.646 0.198,0.198 10 true *c
*a Protrusion *b Cutout
*c Retainer - -
V100135

Push
V100136

Push in


i.

Align the protrusion of the water hose sub-assembly with the cutout in the inlet heater water hose connector and push them together until the inlet heater water hose makes a "click" sound.


ii.

Push in the retainer.


iii.

Check that the water hose sub-assembly and inlet heater water hose connector are securely connected by pulling on them.



Hide 23826 36.INSTALL NO. 1 FUEL VAPOR FEED HOSE

Hide 23827A 37.INSTALL NO. 2 FUEL VAPOR FEED HOSE

Hide 23827F 38.INSTALL NO. 3 FUEL VAPOR FEED HOSE

Hide G922C 39.CONNECT NO. 1 INVERTER COOLING OUTLET HOSE

Hide G922H 40.CONNECT INLET HYBRID RADIATOR HOSE

Hide 16572D 41.CONNECT NO. 2 RADIATOR HOSE

Hide 16571C 42.CONNECT NO. 1 RADIATOR HOSE

Hide 33820B 43.CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

Torque:
12 N*m (122 kgf*cm, 9 ft.*lbf)

Hide G910GB 44.CONNECT INVERTER RESERVE TANK ASSEMBLY

a.
A528167N01
0.406,0.063 0.688,0.417 0.281,0.354 18 false i

i.

Connect the inverter reserve tank assembly with the 2 bolts.

Torque:
5.0 N*m (51 kgf*cm, 44 in.*lbf)

NOTICE:

Temporarily tighten the bolt (A), and then fully tighten the bolt in the order of (B), (A).




Hide 45.CONNECT ENGINE WIRE

Torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)

Hide 82662A 46.INSTALL NO. 1 RELAY BLOCK COVER

Hide G9200 47.INSTALL INVERTER WITH CONVERTER ASSEMBLY

Z101186

Click here(Click here)

Hide 54.INSPECT HYBRID TRANSAXLE FLUID

Z101186

Click here(Click here)

Hide 62.INSPECT FOR EXHAUST GAS LEAK

Z101186

Click here(Click here)

Hide 51444A 65.INSTALL REAR ENGINE UNDER COVER LH

Hide 51443C 66.INSTALL REAR ENGINE UNDER COVER RH

Hide 51410 67.INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

Torque:
7.5 N*m (76 kgf*cm, 66 in.*lbf)

Hide 68.INSTALL FRONT WHEELS

Z101186

Click here(Click here)

Hide 69. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD