RM36D0EC _51 Engine / Hybrid System _083059 M20D-FKS ENGINE MECHANICAL _0403047 ENGINE UNIT A

M20D-FKS ENGINE MECHANICAL  ENGINE UNIT  INSTALLATION  


CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation 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


PROCEDURE

Hide 1.INSTALL WIRE HARNESS CLAMP BRACKET

a.

Install the wire harness clamp bracket to the stiffening crankcase assembly with the bolt.

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


b.

Install the wire harness clamp bracket to the camshaft housing sub-assembly with the bolt.

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


c.

Install the wire harness clamp bracket to the No. 1 ventilation case with the 2 bolts.

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


Hide 2.INSTALL NO. 2 PCV HOSE

a.

Connect the No. 2 PCV hose to the cylinder head cover sub-assembly and slide the clip to secure it.


Hide 25759A 3.INSTALL VACUUM SURGE TANK BRACKET

a.

Install the vacuum surge tank bracket to the cylinder head sub-assembly with the 2 bolts.

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


Hide 17169A 5.INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

a.

Install the No. 3 exhaust manifold heat insulator to the cylinder block sub-assembly with the 2 bolts.

Torque:
16 N*m (163 kgf*cm, 12 ft.*lbf)


Hide 16032 6.INSTALL ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)

a.

Install the engine water pump assembly (water inlet housing) and a new gasket to the cylinder block sub-assembly with the 4 bolts.

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


Hide 11452D 8.INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

a.

Apply a light coat of engine oil to a new O-ring.


b.

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


c.

Install the engine oil level dipstick guide to the cylinder head sub-assembly with the bolt.

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


d.

Install the engine oil level dipstick.


Hide 82126A 18.INSTALL NO. 6 ENGINE WIRE

a.

Install the No. 6 engine wire to the wire harness clamp bracket with the 2 nuts.

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


b.

Attach the 2 clamps.


c.

Connect the 4 connectors.


Hide 82219A 19.INSTALL SENSOR WIRE

a.

Install the sensor wire to the water inlet with thermostat sub-assembly with the bolt.

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


b.

Attach the 3 clamps.


c.

Connect the 4 connectors.


Hide 16260 20.INSTALL WATER BY-PASS HOSE ASSEMBLY

a.

Install the water by-pass hose assembly and slide the 2 clips to secure them.


b.

Install the bolt.

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


Hide 23801P 24.INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

a.
A426800C01
2.74,2.76 2.844,2.594 false 2.896,2.49 3.208,2.646 0.313,0.156 10 false *a 1.604,2.406 1.917,2.563 0.313,0.156 10 false *b
*a 17 mm Union Nut Wrench
*b Torque Wrench Fulcrum Length


Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.

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

NOTICE:

Do not adjust the torque in the loosening direction.


HINT:
·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

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.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)




b.

Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

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

NOTICE:

Do not adjust the torque in the loosening direction.


HINT:
·

Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION

·

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.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)




c.

Install the bolt.

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


Hide 23910A 25.CONNECT FUEL TUBE SUB-ASSEMBLY

a.

Connect the fuel tube sub-assembly to the fuel delivery pipe with sensor assembly.

Click hereEngine / Hybrid System>M20D-FKS (FUEL)>FUEL SYSTEM>PRECAUTION


b.

Install the fuel pipe clamp to the fuel tube connector.


c.

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

Click hereEngine / Hybrid System>M20D-FKS (FUEL)>FUEL SYSTEM>PRECAUTION


Hide 16279 29.INSTALL NO. 3 WATER BY-PASS PIPE

a.

Connect the No. 3 water by-pass pipe to the water outlet and slide the clip to secure it.


b.

Install the No. 3 water by-pass pipe to the intake manifold with the bolt.

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


Hide 35.INSTALL WATER HOSE CLAMP BRACKET

a.

Install the water hose clamp bracket with the 2 bolts.

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


Hide 16260 36.INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

a.
A433284C01
1.917,3.281 1.708,3.281 1.708,3.281 1.469,2.885 true 1.656,2.167 1.958,2.375 0.302,0.208 10 false *a 0.896,2.792 1.219,2.979 0.323,0.188 10 false *b 1.156,2.594 1.417,2.813 0.26,0.219 10 false *c 1.969,3.188 2.281,3.385 0.313,0.198 10 false *d
*a Top
*b Rear
*c 120° (Claw of Clip Location)
*d Paint Mark


Connect the flow shutting valve (water by-pass hose assembly) to the No. 1 water by-pass pipe sub-assembly and slide the clip to secure it.

NOTICE:
·

Make sure to slide the flow shutting valve (water by-pass hose assembly) until it contacts the hose stopper of the No. 1 water by-pass pipe sub-assembly.

·

Make sure that the claws of the clip are within the location shown in the illustration.




b.

Install the flow shutting valve (water by-pass hose assembly) to the water hose clamp bracket with the bolt.

Torque:
19 N*m (194 kgf*cm, 14 ft.*lbf)


Hide 16207 37.INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

a.

Connect the No. 2 water by-pass pipe sub-assembly to the water hose clamp bracket with the bolt.

Torque:
19 N*m (194 kgf*cm, 14 ft.*lbf)


b.
A427767C01
1.417,3.917 1.25,3.917 1.25,3.917 1.042,3.438 true 1.479,3.823 1.792,4.021 0.313,0.198 10 false *a 3,3 3.313,3.198 0.313,0.198 10 false *b 3.021,3.583 3.333,3.781 0.313,0.198 10 false *b
*a Paint Mark
*b 60° (Claw of Clip Location)


Connect the No. 2 water by-pass pipe sub-assembly to the outlet water by-pass sub-assembly and slide the clip to secure it.

NOTICE:
·

Make sure to slide the No. 2 water by-pass pipe sub-assembly until it contacts the hose stopper of the outlet water by-pass sub-assembly.

·

Make sure that the claws of the clip are within the location shown in the illustration.




Hide 16572D 38.CONNECT NO. 2 RADIATOR HOSE

a.

Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.


Hide 16620D 39.INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

NOTICE:
A409240

·

Do not apply or add any oil or grease to the belt tensioner to prevent abnormal noises from the belt tensioner pulley, belt squealing, etc.

·

Do not allow oil or grease to adhere to the moving parts of the belt tensioner, as this may cause malfunctions.



a.

Install the V-ribbed belt tensioner assembly to the No. 2 timing chain cover assembly with the 2 bolts.

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


Hide 43457 43.INSTALL DRIVE SHAFT BEARING BRACKET

a.

Install the drive shaft bearing bracket with the 3 bolts.

Torque:
63.7 N*m (650 kgf*cm, 47 ft.*lbf)