RM35X0E _51 Engine / Hybrid System _078603 7GR-FKS ENGINE MECHANICAL _0381343 ENGINE ASSEMBLY A

7GR-FKS ENGINE MECHANICAL  ENGINE ASSEMBLY  INSTALLATION  


PROCEDURE

Hide 12361E 1.INSTALL FRONT ENGINE MOUNTING INSULATOR

a.
A443696C01
0.031,0.052 0.271,0.271 0.24,0.219 10 true *A 0.042,2.354 0.26,2.583 0.219,0.229 10 false *B
*A for LH Side
*B for RH Side


Install the 2 front engine mounting insulators to the front No. 1 engine mounting bracket RH and front No. 1 engine mounting bracket LH with the 2 nuts.

Torque:
86 N*m (877 kgf*cm, 63 ft.*lbf)


Hide 3.REMOVE ENGINE FROM ENGINE STAND

a.

Attach an engine sling device and hang the engine with a chain block.

NOTICE:

Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger may be damaged or deformed if the angle is incorrect.



b.

Lift the engine and remove it from the engine stand.


c.

Place the engine onto a work bench.


Hide 51100H 4.CONNECT FRONT FRAME ASSEMBLY

a.
A443695C01
0.031,0.031 0.25,0.24 0.219,0.208 10 true *A 0.052,2.354 0.302,2.563 0.25,0.208 10 false *B
*A for LH Side
*B for RH Side


Install the front frame assembly to the engine assembly with the 4 bolts.

Torque:
50 N*m (510 kgf*cm, 37 ft.*lbf)


Hide 32921 12.INSTALL NO. 1 OIL COOLER INLET TUBE AND NO. 1 OIL COOLER OUTLET TUBE (for Automatic Transmission)

Hide 13.INSTALL ENGINE ASSEMBLY WITH AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

a.
A443634C02
0,0 0,0 false
V113146

Place Wooden Block or Plate Attachments


Set the engine on an engine lifter.

NOTICE:
·

Place wooden blocks or plate lift attachments so that the engine is level.

·

With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

·

Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.




b.

Operate the engine lifter and install the engine assembly with automatic transmission assembly to the vehicle.

NOTICE:

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



c.
A443636C01
0,0 0,0 false
V100135

Bolt
V100136

Nut


Install the engine assembly with automatic transmission assembly to the vehicle with the 6 bolts and 2 nuts.

Torque:
188 N*m (1917 kgf*cm, 139 ft.*lbf)


d.
A443635

Install the rear engine mounting member with the 4 bolts.

Torque:
80 N*m (816 kgf*cm, 59 ft.*lbf)


e.

Remove the 4 bolts and 2 engine hangers.


Hide 88539C 14.CONNECT NO. 2 COOLER UNIT DRAIN HOSE (for Automatic Transmission)

a.
A446021

for LHD:

i.

Attach the clamp and connect the No. 2 cooler unit drain hose.



b.
A446022

for RHD:

i.

Attach the clamp and connect the No. 2 cooler unit drain hose.



Hide 82122A 15.CONNECT NO. 2 ENGINE WIRE (for Automatic Transmission)

a.
A443693

Connect the No. 2 engine wire to the vehicle body with the 2 bolts.

Torque:
13 N*m (133 kgf*cm, 10 ft.*lbf)


b.
C411057

Connect the No. 2 engine wire to the automatic transmission assembly with the 2 bolts.

Torque:
13 N*m (133 kgf*cm, 10 ft.*lbf)


Hide 58041C 16.INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR SUB-ASSEMBLY (for Automatic Transmission)

a.
A443692

Install the front No. 1 floor heat insulator sub-assembly with the 3 bolts.

Torque:
5.5 N*m (56 kgf*cm, 49 in.*lbf)


Hide 17.INSTALL ENGINE ASSEMBLY (for Manual Transmission)

a.
A443962C01
0,0 0,0 false
V113146

Place Wooden Block or Plate Attachments


Set the engine on an engine lifter.

NOTICE:
·

Place wooden blocks or plate lift attachments so that the engine is level.

·

With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

·

Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.




b.

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

NOTICE:

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



c.
A443633C01
0,0 0,0 false
V100135

Bolt
V100136

Nut


Install the engine assembly to the vehicle with the 6 bolts and 2 nuts.

Torque:
188 N*m (1917 kgf*cm, 139 ft.*lbf)


d.

Remove the 4 bolts and 2 engine hangers.


Hide 88539C 18.CONNECT NO. 2 COOLER UNIT DRAIN HOSE (for Manual Transmission)

a.
A446021

for LHD:

i.

Attach the clamp and connect the No. 2 cooler unit drain hose.



b.
A446022

for RHD:

i.

Attach the clamp and connect the No. 2 cooler unit drain hose.



Hide 51107D 19.INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

a.
A443632

Install the rear side rail reinforcement sub-assembly RH with the 4 bolts.

Torque:
35 N*m (357 kgf*cm, 26 ft.*lbf)


Hide 51108C 20.INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

a.
A443631

Install the rear side rail reinforcement sub-assembly LH with the 4 bolts.

Torque:
35 N*m (357 kgf*cm, 26 ft.*lbf)


Hide 44402 21.CONNECT NO. 1 POWER STEERING OIL COOLER SUB-ASSEMBLY

a.
A443961C01
0.021,0.031 0.281,0.229 0.26,0.198 10 false *A 0.042,2.271 0.25,2.49 0.208,0.219 10 false *B
*A for Type A
*B for Type B


for LHD:

i.

Connect the No. 1 power steering oil cooler sub-assembly with the 2 bolts.

Torque:
28 N*m (286 kgf*cm, 21 ft.*lbf)



b.
A443629

for RHD:

i.

Connect the No. 1 power steering oil cooler sub-assembly with the 2 bolts.

Torque:
28 N*m (286 kgf*cm, 21 ft.*lbf)



c.
A443960

for LHD:

i.

Connect the return tube sub-assembly to the vehicle body with the bolt.

Torque:
28 N*m (286 kgf*cm, 21 ft.*lbf)



d.
A443628C01
0.042,0.031 0.271,0.24 0.229,0.208 10 true *A 0.042,2.302 0.26,2.49 0.219,0.188 10 false *B
*A for LHD
*B for RHD


Connect the return tube sub-assembly to the vehicle body with the bolt.

Torque:
28 N*m (286 kgf*cm, 21 ft.*lbf)


Hide 53287B 22.INSTALL RADIATOR SUPPORT EXTENSION RH

a.
A443627C01
0.031,0.031 0.25,0.25 0.219,0.219 10 true *A 0.031,2.354 0.302,2.573 0.271,0.219 10 false *B
*A for LHD
*B for RHD


Attach the 2 claws and install the radiator support extension RH.


Hide 53288B 23.INSTALL RADIATOR SUPPORT EXTENSION LH (for LHD)

a.
A443959

Attach the 2 claws and install the radiator support extension LH.


Hide 31250 25.INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)

Hide 31210 26.INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)

Hide 31210 27.INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transmission)

Hide 31470 37.INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transmission)

Hide 31490 38.INSTALL CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transmission)

Hide 31482D 39.INSTALL CLUTCH RELEASE CYLINDER TO ACCUMULATOR TUBE (for Manual Transmission)

Hide 41.INSTALL CLUTCH ACCUMULATOR HEAT INSULATOR SUB-ASSEMBLY (for Manual Transmission)

Hide 43.INSTALL FRONT AXLE ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.


Hide 48820B 45.INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.


Hide 48068 47.INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.


Hide 50.CONNECT FRONT DISC BRAKE CALIPER ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.


Hide 45046 52.CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT:

Use the same procedure described for the LH side.


Hide 89542 54.INSTALL FRONT SPEED SENSOR RH

HINT:

Use the same procedure described for the LH side.


Hide 11409 66.INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

a.
A437910

Install the O-ring to the engine oil level dipstick guide.


b.

Install the engine oil level dipstick guide with the bolt.

Torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)


c.

Install the engine oil level dipstick.


Hide 17346 75.CONNECT NO. 6 AIR INJECTION SYSTEM HOSE (w/ Secondary Air Injection System)

a.
A443624

Connect the No. 6 air injection system hose to the air tube assembly, and slide the clip to secure it.


Hide 16631D 76.INSTALL NO. 1 IDLER PULLEY BRACKET (w/o Air Conditioning System)

a.
A443948

Install the No. 1 idler pulley bracket with the 3 bolts.

Torque:
24.5 N*m (250 kgf*cm, 18 ft.*lbf)


Hide 16603K 77.INSTALL IDLER PULLEY SUB-ASSEMBLY (w/o Air Conditioning System)

a.
A444015C01
2.333,0.292 2.521,0.292 2.521,0.292 2.885,0.625 false 2.375,1.552 2.375,1.125 false 1.615,1.906 1.615,1.656 false 0.927,1.729 0.927,1.396 false 0.25,1.771 0.25,1.438 false 0.188,1.792 0.396,1.979 0.208,0.188 10 false *1 0.865,1.75 1.052,1.938 0.188,0.188 10 false *2 1.563,1.938 1.75,2.115 0.188,0.177 10 false *3 2.146,0.198 2.333,0.385 0.188,0.188 10 false *4 2.333,1.583 2.531,1.781 0.198,0.198 10 false *2
*1 Bolt
*2 Plate Washer
*3 Idler Pulley Sub-assembly
*4 No. 1 Idler Pulley Bracket


Install the 2 plate washers and idler pulley sub-assembly to the No. 1 idler pulley bracket with the bolt as shown in the illustration.

Torque:
60 N*m (612 kgf*cm, 44 ft.*lbf)


Hide 88320 78.INSTALL COMPRESSOR ASSEMBLY WITH MAGNET CLUTCH (w/ Air Conditioning System)

Hide 23901 84.CONNECT FUEL TUBE SUB-ASSEMBLY


b.
A443621

Install the No. 2 fuel pipe clamp.


Hide 87245A 85.CONNECT HEATER WATER HOSE ASSEMBLY

a.
A443623

Connect the 2 heater water hose assemblies to the water pipe, and slide the 2 clamps to secure the hoses.


Hide 86.CONNECT WIRE HARNESS

a.
A443618

Attach the claw and 3 connectors from the No. 1 engine room relay block.


b.

Attach the clamp and connect the wire harness to the bracket.


c.
A443617

Connect the wire harness to the body with the 2 bolts.

Torque:
14 N*m (143 kgf*cm, 10 ft.*lbf)


d.

Connect the connector.


e.

Attach the 3 clamps and connect the wire harness to the No. 1 engine room relay block and bracket.


f.
A443616

Connect the 2 wire harnesses to the No. 1 engine room relay assembly with the 2 bolts.

Torque:
8.3 N*m (85 kgf*cm, 73 in.*lbf)


g.
A443615

Attach the claw and install the relay block cover to the No. 1 engine room relay block.


h.
A443614

Attach the 2 claws and install the upper No. 1 relay block cover to the No. 1 engine room relay block.


Hide 82121 87.CONNECT ENGINE WIRE

a.

Pass the engine wire into the cabin.


b.

Attach the grommet to the body.


c.
A443619C01
0.042,0.042 0.26,0.26 0.219,0.219 10 true *A 0.063,2.49 0.323,2.719 0.26,0.229 10 false *B
*A for LHD
*B for RHD


for LHD:

Attach the 2 clamps to connect the engine wire to the bracket.


d.

for RHD:

Attach the clamp to connect the engine wire to the bracket.


e.
A443620C01
0.031,0.042 0.271,0.25 0.24,0.208 10 true *A 0.042,2.469 0.26,2.667 0.219,0.198 10 false *B
*A for LHD
*B for RHD


Connect the 2 connectors to the instrument panel wire.



Hide 32941 89.INSTALL NO. 1 OIL COOLER INLET HOSE AND NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transmission)

Hide 17881 95.INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

a.
A443626

Install the air cleaner assembly with air cleaner hose with the 3 bolts.

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


b.

Tighten the hose clamp.

Torque:
4.0 N*m (41 kgf*cm, 35 in.*lbf)


c.

Connect the No. 2 PCV hose to the No. 1 air cleaner hose, and slide the clamp to secure the hose.


d.
A443625

Attach the 2 wire harness clamps.


e.

Connect the mass air flow meter sub-assembly connector.


Hide 11209 97.INSTALL V-BANK COVER SUB-ASSEMBLY (w/ Cover)

a.

Attach the 3 clips to install the V-bank cover sub-assembly.

NOTICE:
·

Securely attach the clips.

·

If the clips are forcibly attached or struck with an object, they may be damaged.




Hide 55701J 98.INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

a.
A442627C01
0.073,0.094 0.323,0.26 0.25,0.167 10 true *A 0.083,2.594 0.344,2.75 0.26,0.156 10 true *B
*A for LHD
*B for RHD


Install the outer cowl top panel sub-assembly with the 10 bolts.

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


b.
A443606C01
0.031,0.031 0.271,0.25 0.24,0.219 10 true *A 0.042,2.51 0.26,2.719 0.219,0.208 10 true *B
*A for LHD
*B for RHD


for LHD:

i.

Attach the 6 clamps and connect the wire harness to the outer cowl top panel sub-assembly.



c.

for RHD:

i.

Attach the 7 clamps and connect the wire harness to the outer cowl top panel sub-assembly.



Hide 55738D 99.INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL

a.
A443608C01
0.042,0.031 0.281,0.25 0.24,0.219 10 true *A 0.042,2.385 0.302,2.615 0.26,0.229 10 false *B
*A for LHD
*B for RHD


for LH Side:

i.

Attach the 2 claws and install the No. 2 heater air duct splash shield seal to the outer cowl top panel sub-assembly.



b.
A443607C01
0.042,0.031 0.281,0.271 0.24,0.24 10 false *A 0.063,2.385 0.281,2.594 0.219,0.208 10 false *B
*A for LHD
*B for RHD


for RH Side:

i.

Attach the 2 claws and install the No. 2 heater air duct splash shield seal to the outer cowl top panel sub-assembly.



Hide 47220D 100.CONNECT BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

a.
A443605C01
0.042,0.031 0.271,0.26 0.229,0.229 10 true *A 0.052,2.344 0.302,2.542 0.25,0.198 10 false *B
*A for LHD
*B for RHD


Connect the brake master cylinder reservoir assembly with the 2 bolts.

Torque:
8.5 N*m (87 kgf*cm, 75 in.*lbf)


b.
A443604C01
0.042,0.042 0.281,0.26 0.24,0.219 10 true *A 0.042,2.396 0.26,2.604 0.219,0.208 10 false *B
*A for LHD
*B for RHD


Disconnect the connector.


c.

for RHD:

i.

Attach the clamp and connect the wire harness to the brake master cylinder reservoir assembly.



Hide 103. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL

Hide 104.BLEED CLUTCH PIPE LINE (for Manual Transmission)

Hide 31301 107.INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY (for Manual Transmission)

Hide 108.CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (w/ Air Conditioning System)

Hide 125. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

Hide 51773E 130.INSTALL STEP PLATE COVER RH (w/ Cover)

a.
A443964C01
0.813,0.823 1.031,1.031 0.219,0.208 10 true *A 1.094,0.823 1.313,1.031 0.219,0.208 10 true *B
*A for Automatic Transmission
*B for Manual Transmission


Install the step plate cover RH with the 4 clips and 5 bolts.

Torque:
5.5 N*m (56 kgf*cm, 49 in.*lbf)


Hide 51407A 131.INSTALL NO. 3 ENGINE UNDER COVER SUB-ASSEMBLY (w/ No. 3 Engine Under Cover Sub-assembly)

a.
A443612C01
0.042,0.031 0.271,0.24 0.229,0.208 10 true *A 0.052,2.365 0.281,2.563 0.229,0.198 10 false *B
*A for Manual Transmission
*B for Automatic Transmission


Install the No. 3 engine under cover sub-assembly with the 4 bolts.

Torque:
13 N*m (133 kgf*cm, 10 ft.*lbf)


Hide 51405A 132.INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

a.
A443699

w/ No. 2 Engine Under Cover Sub-assembly:

i.

Attach the guide and install the No. 1 engine under cover sub-assembly.


ii.

Install the 10 clips.



b.
A443613

w/o No. 2 Engine Under Cover Sub-assembly:

i.

Attach the guide and install the No. 1 engine under cover sub-assembly.


ii.

Install the 12 clips and 2 bolts.

Torque:
5.5 N*m (56 kgf*cm, 49 in.*lbf)



Hide 52618 133.INSTALL LOWER FRONT BUMPER ABSORBER

a.
A443610C01
0,0 0,0 false
V100135

Bolt
V100136

Screw


Attach the 2 guides and install the lower front bumper absorber.


b.

Install the 4 bolts, 4 screws and 4 clips.

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


Hide 51406A 134.INSTALL NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (w/ No. 2 Engine Under Cover Sub-assembly)

a.
A443611

Install the No. 2 engine under cover sub-assembly with the 6 clips and 7 bolts.

Torque:
5.5 N*m (56 kgf*cm, 49 in.*lbf)