RM38N0EC _51 Engine / Hybrid System _111786 M20C-FKS, M20D-FKS ENGINE MECHANICAL _0499722 ENGINE ASSEMBLY A

M20C-FKS, M20D-FKS 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 or the engine assembly with transaxle may fall off the engine lifter.

·

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

PROCEDURE

Hide Display 12372A 1.INSTALL ENGINE MOUNTING INSULATOR LH

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

2.25,0.354 2.406,0.552 0.156,0.198 10 true A 2.604,1.896 2.76,2.094 0.156,0.198 10 true B 1.313,0.229 1.469,0.427 0.156,0.198 10 true D 1.083,1.885 1.24,2.083 0.156,0.198 10 true C

Install the engine mounting insulator LH to the vehicle body with the 4 bolts.

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

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

Hide Display 12341 2.INSTALL ENGINE MOUNTING SPACER

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

1,1.854 1.156,2.052 0.156,0.198 10 true A 2.813,1.458 2.969,1.656 0.156,0.198 10 true B

Install the engine mounting spacer to the vehicle body with the 2 bolts.

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

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

Hide Display 12305 3.INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

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

0.75,1.104 0.906,1.302 0.156,0.198 10 true A 2.573,1.167 2.729,1.365 0.156,0.198 10 true B 2.521,0.615 2.677,0.813 0.156,0.198 10 true C

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

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).

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

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

0.979,1.969 1.135,2.167 0.156,0.198 10 true 1 2.521,1.125 2.677,1.323 0.156,0.198 10 true 2

Install the radiator reserve tank assembly with the bolt and nut in the order shown in the illustration.

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

Engage the 2 clamps.

Hide Display 4.INSTALL ENGINE HANGERS

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE ASSEMBLY>REMOVAL202409,999999,_51,_111786,_0499722,RM100000002OLFC_01_0270,

Hide Display 5.REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

Remove the engine assembly from the engine stand.

Hide Display 82121 6.INSTALL ENGINE WIRE

Install the engine wire to the engine assembly.

Hide Display 19315 7.INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>REAR CRANKSHAFT OIL SEAL>INSTALLATION202111,999999,_51,_111786,_0499721,RM100000001YZIC_01_0018,

Hide Display 32101B 8.INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>REAR CRANKSHAFT OIL SEAL>INSTALLATION202111,999999,_51,_111786,_0499721,RM100000001YZIC_01_0017,

Hide Display 9.INSTALL ENGINE ASSEMBLY

Click hereDrivetrain>K120 / K120F / K121 / K121F (CVT)>CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY>INSTALLATION202409,999999,_52,_111806,_0499728,RM100000002OREG_01_0047,

Hide Display 37117 10.INSTALL PROPELLER SHAFT HEAT INSULATOR (for AWD)

Click hereDrivetrain>GF1A (TRANSFER / 4WD / AWD)>TRANSFER ASSEMBLY>INSTALLATION202203,999999,_52,_119335,_0524095,RM1000000021Z69_01_0018,

Hide Display 11.INSTALL WIRE HARNESS CLAMP BRACKET

Click hereDrivetrain>K120 / K120F / K121 / K121F (CVT)>CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY>INSTALLATION202409,999999,_52,_111806,_0499728,RM100000002OREG_01_0003,

Hide Display 28100 12.INSTALL STARTER ASSEMBLY

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (STARTING)>STARTER (for 1.2 kW Type)>INSTALLATION202406,999999,_51,_111788,_0702411,RM100000002MQLA_01_0018,

Hide Display 11363A 13.INSTALL FLYWHEEL HOUSING SIDE COVER

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (STARTING)>STARTER (for 1.2 kW Type)>INSTALLATION202406,999999,_51,_111788,_0702411,RM100000002MQLA_01_0021,

Hide Display 12371A 14.INSTALL REAR ENGINE MOUNTING INSULATOR

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

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>ACTIVE CONTROL ENGINE MOUNT (for Rear Side)>INSTALLATION202111,999999,_51,_111785,_0503270,RM100000001ZE1C_01_0002,

Hide Display 12361 15.INSTALL FRONT ENGINE MOUNTING INSULATOR

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

Install the front engine mounting insulator to the front frame assembly with the 3 nuts.

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

Hide Display 12311A 16.INSTALL FRONT ENGINE MOUNTING BRACKET

Click hereDrivetrain>K120 / K120F / K121 / K121F (CVT)>CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY>INSTALLATION202409,999999,_52,_111806,_0499728,RM100000002OREG_01_0097,

Hide Display 51100G 17.INSTALL FRONT FRAME ASSEMBLY

Install the rear engine mounting insulator to the front frame assembly with the 4 nuts.

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

Install the front engine mounting insulator to the front engine mounting bracket with the bolt.

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

Engage the wire harness clamp to connect the vacuum switching valve (for active control engine mount system) connector.

Hide Display 18.CONNECT ENGINE WIRE

Click hereDrivetrain>K120 / K120F / K121 / K121F (CVT)>CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY>INSTALLATION202409,999999,_52,_111806,_0499728,RM100000002OREG_01_0099,

Hide Display 19.INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

Install the water by-pass pipe sub-assembly with the 3 bolts.

4.542,2.063 4.698,1.74 4.698,1.74 4.854,1.74 true 4.323,1.917 4.167,1.354 4.167,1.354 3.958,1.354 true 3.281,2.583 3.281,3.448 true 6.083,1.719 5.656,1.656 5.656,1.656 6.073,1.542 false 2.188,2.896 2.375,2.49 false 0.938,1.115 1.125,0.708 false 0.615,1.125 0.49,0.719 false 1.865,2.865 1.74,2.458 false 4.927,1.677 5.167,1.833 0.24,0.156 10 false *1 3.75,1.292 4.063,1.448 0.313,0.156 10 false *2 3.208,3.479 3.521,3.635 0.313,0.156 10 true *3 0.813,1.74 1.021,1.917 0.208,0.177 10 false *a 1.521,0.813 1.833,0.969 0.313,0.156 10 false *b 0.396,0.552 0.708,0.708 0.313,0.156 10 false *c 1.594,1.083 1.771,1.229 0.177,0.146 10 true *f 1.156,2.854 1.344,3.01 0.188,0.156 10 true *e 1.865,3.5 2.073,3.677 0.208,0.177 10 false *a 6.698,1.458 6.906,1.635 0.208,0.177 10 false *a 1.365,2.427 1.677,2.583 0.313,0.156 10 false *b 5.542,2.021 5.854,2.177 0.313,0.156 10 false *b 5.427,1.583 5.74,1.74 0.313,0.156 10 false *c 2.333,2.333 2.646,2.49 0.313,0.156 10 false *c 6.042,2.177 6.229,2.333 0.188,0.156 10 true *d 1.094,0.563 1.406,0.719 0.313,0.156 10 false *g 1.635,2.281 1.948,2.438 0.313,0.156 10 false *g 3.906,2 4.052,2.146 0.146,0.146 10 true A 3.719,3.219 3.865,3.365 0.146,0.146 10 true B 4.031,2.521 4.177,2.667 0.146,0.146 10 true C

*1	Water By-pass Hose Assembly	*2	No. 3 Water By-pass Hose
*3	No. 4 Water By-pass Hose	-	-
*a	2 to 7 mm (0.0787 to 0.276 in.)	*b	120°
*c	Paint Mark	*d	Rear Side of Vehicle
*e	Upper Side	*f	RH Side of Vehicle
*g	Protrusion	-	-

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

NOTICE:: Temporarily tighten the bolt (A), and then fully tighten the 3 bolts in the order of (B), (C) and (A).

Connect the water by-pass hose assembly, No. 3 water by-pass hose and No. 4 water by-pass hose and slide the 3 clips to secure them.

NOTICE:: ·

Make sure to slide the water by-pass hose assembly, No. 3 water by-pass hose and No. 4 water by-pass hose until they contact the hose stoppers.

·

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

Hide Display 20.CONNECT VACUUM HOSE

for 2WD:

Engage the 5 clamps.

ii.

Connect the vacuum hose to the rear engine mounting insulator.

for AWD:

Engage the 3 clamps.

Hide Display 16261G 21.INSTALL NO. 1 WATER BY-PASS HOSE

Install the No. 1 water by-pass hose and slide the 2 clips to secure it.

1.583,1.813 2.104,1.854 2.104,1.854 1.573,1.969 false 5.417,1.521 5.406,2.115 5.406,2.115 5.042,1.51 false 0.792,1.896 1.104,2.052 0.313,0.156 10 false *a 1.885,1.375 2.198,1.531 0.313,0.156 10 false *b 2.156,1.792 2.469,1.948 0.313,0.156 10 false *c 1.49,1.188 1.729,1.333 0.24,0.146 10 true *d 5.854,1.417 6.083,1.573 0.229,0.156 10 true *e 5.208,0.75 5.521,0.906 0.313,0.156 10 false *a 5.635,1.219 5.948,1.375 0.313,0.156 10 false *b 5.375,2.146 5.688,2.302 0.313,0.156 10 false *c

*a	2 to 7 mm (0.0787 to 0.276 in.)	*b	120°
*c	Paint Mark	*d	LH Side of Vehicle
*e	Upper Side	-	-

NOTICE:: ·

Make sure to slide the No. 1 water by-pass hose until it contacts the hose stopper.

·

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

Engage the 2 clamps.

Hide Display 32101G 22.INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

Click hereDrivetrain>K120 / K120F / K121 / K121F (CVT)>CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY>INSTALLATION202409,999999,_52,_111806,_0499728,RM100000002OREG_01_0064,

Hide Display 11361J 23.INSTALL FLYWHEEL HOUSING UNDER COVER

Click hereDrivetrain>K120 / K120F / K121 / K121F (CVT)>CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY>INSTALLATION202409,999999,_52,_111806,_0499728,RM100000002OREG_01_0065,

Hide Display 24.INSTALL EMISSION CONTROL VALVE BRACKET

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (EMISSION CONTROL)>DIFFERENTIAL PRESSURE SENSOR>INSTALLATION202303,999999,_51,_111790,_0588333,RM1000000029YZS_01_0035,

Hide Display 89481B 25.INSTALL DIFFERENTIAL PRESSURE SENSOR

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (EMISSION CONTROL)>DIFFERENTIAL PRESSURE SENSOR>INSTALLATION202303,999999,_51,_111790,_0588333,RM1000000029YZS_01_0001,

Hide Display 26.INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

HINT:: Perform "Inspection After Repair" after replacing the engine assembly.; Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION202303,999999,_51,_111785,_0504416,RM1000000029BFF,

Set the engine assembly with transaxle on an engine lifter.

NOTICE:: ·

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

·

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.

Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.

Install the fuel delivery guard to the engine mounting bracket RH with the bolt.

Torque:: 40 N*m (408 kgf*cm, 30 ft.*lbf)

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 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.

1.979,1.75 2.198,1.75 2.198,1.75 2.396,1.333 true 1.438,1.75 1.208,1.75 1.208,1.75 1.021,1.458 true 1.99,4.563 2.208,4.563 2.208,4.563 2.313,4.313 true 1.438,4.542 1.208,4.542 1.208,4.542 1.073,4.302 true 1.01,0.844 1.167,1.042 0.156,0.198 10 false . 0.354,2.948 0.51,3.146 0.156,0.198 10 true A 3,2.927 3.156,3.125 0.156,0.198 10 true A 1.073,1.063 1.229,1.26 0.156,0.198 10 true B 2.292,0.99 2.448,1.188 0.156,0.198 10 true B 1.5,4.229 1.656,4.427 0.156,0.198 10 true C 1.771,4.24 1.927,4.438 0.156,0.198 10 true C 0.406,4.021 0.563,4.219 0.156,0.198 10 true D 0.438,4.417 0.594,4.615 0.156,0.198 10 true D 2.875,4.042 3.031,4.24 0.156,0.198 10 true D 2.844,4.417 3,4.615 0.156,0.198 10 true D 1.792,1.656 1.948,1.854 0.156,0.198 10 false *1 1.49,1.656 1.646,1.854 0.156,0.198 10 false *2 1.76,4.469 1.979,4.656 0.219,0.188 10 true *3 1.458,4.448 1.656,4.667 0.198,0.219 10 true *4

*1	Front Bumper Extension Sub-assembly LH
*2	Front Bumper Extension Sub-assembly RH
*3	Rear Front Suspension Member Brace LH
*4	Rear Front Suspension Member Brace RH
	Bolt
	Nut

Install the front bumper extension sub-assembly LH and front bumper extension sub-assembly RH to the front frame assembly and vehicle body with the 2 bolts (A), 2 bolts (B) and 4 nuts.

Torque:: Bolt (A) : 135 N*m (1377 kgf*cm, 100 ft.*lbf); Bolt (B) : 9.5 N*m (97 kgf*cm, 84 in.*lbf); Nut : 12.5 N*m (127 kgf*cm, 9 ft.*lbf)

Install the rear front suspension member brace LH and rear front suspension member brace RH to the front frame assembly and vehicle body with the 2 bolts (C) and 4 bolts (D).

Torque:: Bolt (C) : 135 N*m (1377 kgf*cm, 100 ft.*lbf); Bolt (D) : 60 N*m (612 kgf*cm, 44 ft.*lbf)

Install the engine mounting insulator LH to the engine mounting bracket sub-assembly LH with the bolt and nut.

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

Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 3 bolts and nut.

Torque:: Bolt : 72 N*m (734 kgf*cm, 53 ft.*lbf); Nut : 42 N*m (428 kgf*cm, 31 ft.*lbf)

Hide Display 37110 27.INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for AWD)

Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>PROPELLER SHAFT ASSEMBLY>INSTALLATION202203,999999,_52,_111807,_0525508,RM10000000227DJ,

Hide Display 28.INSTALL FRONT DRIVE SHAFT ASSEMBLY

Click hereDrivetrain>DRIVE SHAFT / PROPELLER SHAFT>FRONT DRIVE SHAFT ASSEMBLY>INSTALLATION202203,999999,_52,_111807,_0503131,RM100000002299I,

Hide Display 17410 29.INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (INTAKE / EXHAUST)>EXHAUST MANIFOLD>INSTALLATION202303,999999,_51,_111792,_0503718,RM1000000029Z2I_01_0218,

Hide Display 45220 30.CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

Click hereSteering>STEERING GEAR / LINKAGE>STEERING GEAR>INSTALLATION202111,999999,_55,_111821,_0503296,RM100000001ZE39_01_0176,

Hide Display 16282F 31.CONNECT NO. 5 WATER BY-PASS HOSE

Connect the No. 5 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.

5.26,0.781 5.552,0.396 true 5.198,0.771 4.938,0.406 true 5.125,1.375 5.438,1.531 0.313,0.156 10 false *a 4.76,0.292 5.073,0.448 0.313,0.156 10 false *b 5.594,0.313 5.906,0.469 0.313,0.156 10 false *c

*a	2 to 7 mm (0.0787 to 0.276 in.)	*b	Paint Mark
*c	Protrusion	-	-

NOTICE:: Make sure to slide the No. 5 water by-pass hose until it contacts the hose stopper.

Hide Display 32.CONNECT WIRE HARNESS

Engage the clamp to connect the wire harness to the vehicle body.

Install the bolt.

Torque:: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Engage the clamp to connect the wire harness to the continuously variable transaxle assembly.

Install the bolt.

Torque:: 20 N*m (204 kgf*cm, 15 ft.*lbf)

Engage the claw to connect the wire harness to the No. 1 engine room relay block assembly and No. 1 engine room junction block assembly.

Connect the 5 connectors to the No. 1 engine room relay block assembly and No. 1 engine room junction block assembly.

Connect the wire harness to the No. 1 engine room relay block assembly and No. 1 engine room junction block assembly with the nut.

Torque:: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Install the No. 1 relay block cover to the No. 1 engine room relay block assembly and No. 1 engine room junction block assembly.

Hide Display 88711 33.CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for M20C-FKS, M20D-FKS)>INSTALLATION202111,999999,_58,_111841,_0499798,RM100000001Z093_01_0002,

Hide Display 88704 34.CONNECT SUCTION HOSE SUB-ASSEMBLY

Click hereVehicle Interior>HEATING / AIR CONDITIONING>COMPRESSOR (for M20C-FKS, M20D-FKS)>INSTALLATION202111,999999,_58,_111841,_0499798,RM100000001Z093_01_0003,

Hide Display 16572D 35.CONNECT NO. 2 RADIATOR HOSE

Connect the No. 2 radiator hose to the water inlet with thermostat sub-assembly and slide the clip to secure it.

4.427,0.865 4.729,1.063 true 4.438,0.792 4.688,0.719 true 3.698,0.781 4.01,0.938 0.313,0.156 10 false *a 5.094,0.406 5.406,0.563 0.313,0.156 10 false *b 4.781,1.021 5.094,1.177 0.313,0.156 10 false *c 4.74,0.646 5.052,0.802 0.313,0.156 10 false *d 5.563,0.573 5.75,0.76 0.188,0.188 10 true *e

*a	2 to 7 mm (0.0787 to 0.276 in.)	*b	120°
*c	Paint Mark	*d	Protrusion
*e	Upper Side	-	-

NOTICE:: ·

Make sure to slide the No. 2 radiator hose until it contacts the hose stopper.

·

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

Hide Display 16571C 36.CONNECT NO. 1 RADIATOR HOSE

Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.

4.458,0.792 4.76,0.958 true 4.458,0.74 4.698,0.635 true 3.698,0.719 4.01,0.875 0.313,0.156 10 false *a 5.188,0.292 5.5,0.448 0.313,0.156 10 false *b 4.813,0.896 5.125,1.052 0.313,0.156 10 false *c 4.74,0.563 5.052,0.719 0.313,0.156 10 false *d 5.583,0.521 5.771,0.677 0.188,0.156 10 true *e

*a	2 to 7 mm (0.0787 to 0.276 in.)	*b	120°
*c	Paint Mark	*d	Protrusion
*e	Upper Side	-	-

NOTICE:: ·

Make sure to slide the No. 1 radiator hose until it contacts the hose stopper.

·

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

Hide Display 23901 37.CONNECT FUEL TUBE SUB-ASSEMBLY

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

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>PRECAUTION202111,999999,_51,_111793,_0504174,RM100000001ZHDE,

Install the No. 1 fuel pipe clamp to the fuel tube connector.

Hide Display 87245 38.CONNECT INLET HEATER WATER HOSE

1.01,0.979 1.438,0.979 false 1.875,0.969 2.302,0.969 false 1.021,1.354 1.448,1.354 false 1.844,1.365 2.281,1.917 2.281,1.917 2.594,1.917 false 0.813,0.885 1.125,1.042 0.313,0.156 10 false *a 0.833,1.271 1.146,1.427 0.313,0.156 10 false *b 2.365,0.896 2.677,1.052 0.313,0.156 10 false *a 2.635,1.844 2.948,2 0.313,0.156 10 false *b

*a	Protrusion
*b	Cutout

Align the protrusions of the inlet heater water hose connector with the cutouts in the flow shutting valve (water by-pass hose assembly) and push them together until the inlet heater water hose connector makes a "click" sound.

0.823,0.896 1.167,0.896 1.167,0.896 1.51,1.427 true 0.594,0.813 0.833,1.01 0.24,0.198 10 true *a

*a	Retainer
	Push
	Push in

Push in the retainer.

Check that the flow shutting valve (water by-pass hose assembly) and inlet heater water hose connector are securely connected by pulling on them.

Hide Display 87246 39.CONNECT OUTLET HEATER WATER HOSE

1.052,1.156 1.573,1.156 false 0.99,0.365 1.219,0.365 1.219,0.365 1.521,0.792 false 0.875,1.063 1.188,1.219 0.313,0.156 10 false *a 0.823,0.281 1.135,0.438 0.313,0.156 10 false *b

*a	Protrusion
*b	Cutout

Align the protrusion of the No. 2 water by-pass pipe sub-assembly with the cutout in the outlet heater water hose connector and push them together until the outlet heater water hose connector makes a "click" sound.

1.49,1.604 1.75,2.021 1.75,2.021 2.063,2.021 true 2.115,1.948 2.354,2.135 0.24,0.188 10 true *a

*a	Retainer
	Push
	Push in

Push in the retainer.

Check that the No. 2 water by-pass pipe sub-assembly and outlet heater water hose connector are securely connected by pulling on them.

Hide Display 44777 40.CONNECT NO. 1 VACUUM HOSE CONNECTOR

Connect the No. 1 vacuum hose connector to the vacuum pump assembly.

Engage the clamp.

Hide Display 23826 41.CONNECT NO. 1 FUEL VAPOR FEED HOSE

Connect the No. 1 fuel vapor feed hose to the purge valve (purge VSV) and slide the clip to secure it.

5.083,0.656 5.396,0.854 0.313,0.198 10 false *a 4.521,1.417 4.833,1.615 0.313,0.198 10 false *b

120°

2 to 7 mm (0.0787 to 0.276 in.)

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

Hide Display 33820B 42.CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

NOTICE:: Before connecting the transmission control cable assembly, check that the shift lever is in N.

0.49,1.448 0.708,1.656 0.219,0.208 10 true *a

Turn the transmission control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.

NOTICE:

1.615,0.552 1.823,0.25 1.823,0.25 1.99,0.25 true 1.958,1.344 2.25,0.938 2.25,0.938 2.729,0.938 true 1.531,1.813 1.99,1.813 true 2.042,0.146 2.323,0.385 0.281,0.24 10 false *1 2.792,0.813 3.073,1.052 0.281,0.24 10 false *a 1.323,1.708 1.521,1.938 0.198,0.229 10 true *b

*1	Transmission Control Shaft Lever
*a	Manual Valve Link Lever Sub-assembly
*b	Manual Valve

If the transmission control shaft lever is turned counterclockwise more than necessary, manual valve link lever sub-assembly may separate from the manual valve.

0.729,2.906 1.042,3.063 0.313,0.156 10 false *a 2.063,2.896 2.375,3.052 0.313,0.156 10 false *b

*a	Correct
*b	Incorrect

Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

Connect the transmission control cable assembly to the transmission control shaft lever as shown in the illustration.

Hide Display 74404B 43.INSTALL BATTERY CLAMP SUB-ASSEMBLY

Install the battery clamp sub-assembly with the 3 bolts.

Torque:: 18.5 N*m (189 kgf*cm, 14 ft.*lbf)

Engage the 2 claws and connect the engine room main wire to the No. 2 engine wire.

Connect the engine room main wire and No. 2 engine wire to the positive (+) battery terminal with the nut.

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

Engage the 2 clamps to connect the engine room main wire and No. 2 engine wire to the battery clamp sub-assembly.

Engage the 2 clamps to the battery clamp sub-assembly.

Hide Display 89661 44.INSTALL ECM

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>ECM>INSTALLATION202303,999999,_51,_111785,_0503271,RM1000000029P3V_01_0001,

Hide Display 45.INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>THROTTLE BODY>INSTALLATION202111,999999,_51,_111785,_0503267,RM100000001ZE12_01_0037,

Hide Display 17750A 46.INSTALL INLET AIR CLEANER ASSEMBLY

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>THROTTLE BODY>INSTALLATION202111,999999,_51,_111785,_0503267,RM100000001ZE12_01_0036,

Hide Display 12601B 47.INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

Align the center of the grommet hole of the No. 1 engine cover sub-assembly with the oil filler cap assembly, then align the 3 clips and install the No. 1 engine cover sub-assembly.

NOTICE:: ·

Securely engage the clips.

·

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

Hide Display 48.INSPECT VACUUM HOSES

Inspect the vacuum hoses.

1.24,0.25 1.615,0.49 0.375,0.24 12 false *A 1.365,3.052 1.74,3.292 0.375,0.24 12 false *B

for 2WD

for AWD

Hide Display 49.INSTALL BATTERY

Click hereGeneral>MAINTENANCE>M20C-FKS, M20D-FKS BATTERY>INSTALLATION202111,999999,_V1,_112220,_0503321,RM100000001ZE56,

Hide Display 50.INSPECT SHIFT LEVER POSITION

Click hereDrivetrain>K120 / K120F / K121 / K121F (CVT)>SHIFT LEVER>ON-VEHICLE INSPECTION202303,999999,_52,_111806,_0499742,RM100000002B6HZ_01_0003,

Hide Display 51.ADJUST SHIFT LEVER POSITION

Click hereDrivetrain>K120 / K120F / K121 / K121F (CVT)>TRANSMISSION CONTROL CABLE (for SFTM Made)>ADJUSTMENT202303,999999,_52,_111806,_0499741,RM100000002B6JJ_01_0011,

Hide Display 52.ADD ENGINE OIL

Click hereGeneral>MAINTENANCE>M20C-FKS, M20D-FKS OIL AND OIL FILTER>REPLACEMENT202303,999999,_V1,_112220,_0503319,RM100000002BF30_02_0005,

Hide Display 53.ADD TRANSFER OIL (for AWD)

Click hereGeneral>MAINTENANCE>GF1A TRANSFER OIL>REPLACEMENT202203,999999,_V1,_112220,_0524113,RM1000000021Z8G_01_0002,

Hide Display 54.ADD ENGINE COOLANT

Click hereGeneral>MAINTENANCE>M20C-FKS, M20D-FKS COOLANT>REPLACEMENT202111,999999,_V1,_112220,_0503655,RM100000001ZFD9_02_0002,

Hide Display 55.ADJUST CONTINUOUSLY VARIABLE TRANSAXLE FLUID

Click hereDrivetrain>K120 / K120F / K121 / K121F (CVT)>CONTINUOUSLY VARIABLE TRANSAXLE FLUID>ADJUSTMENT202303,999999,_52,_111806,_0499727,RM100000002A0IE,

Hide Display 56.CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>REPLACEMENT202111,999999,_58,_111841,_0499789,RM100000001Z086_01_0002,

Hide Display 57. WARM UP ENGINE

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>REPLACEMENT202111,999999,_58,_111841,_0499789,RM100000001Z086_01_0008,

Hide Display 58.INSPECT FOR FUEL LEAK

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL SYSTEM>ON-VEHICLE INSPECTION202111,999999,_51,_111793,_0504174,RM100000001ZHDC_01_0001,

Hide Display 59.INSPECT FOR ENGINE OIL LEAK

Click hereGeneral>MAINTENANCE>M20C-FKS, M20D-FKS OIL AND OIL FILTER>REPLACEMENT202303,999999,_V1,_112220,_0503319,RM100000002BF30_02_0006,

Hide Display 60.INSPECT FOR COOLANT LEAK

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (COOLING)>COOLING SYSTEM>ON-VEHICLE INSPECTION202111,999999,_51,_111791,_0503624,RM100000001ZF95_01_0001,

Hide Display 61.INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAKS

Hide Display 62.INSPECT FOR REFRIGERANT LEAK

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>REPLACEMENT202111,999999,_58,_111841,_0499789,RM100000001Z086_01_0004,

Hide Display 63.INSPECT FOR EXHAUST GAS LEAK

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (INTAKE / EXHAUST)>EXHAUST PIPE>INSTALLATION202303,999999,_51,_111792,_0503719,RM1000000029Z2O_01_0041,

Hide Display 64.CHECK ENGINE OIL LEVEL

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (LUBRICATION)>LUBRICATION SYSTEM>ON-VEHICLE INSPECTION202303,999999,_51,_111787,_0503323,RM100000002BF3T_01_0001,

Hide Display 65.INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (COOLING)>COOLING SYSTEM>ON-VEHICLE INSPECTION202111,999999,_51,_111791,_0503624,RM100000001ZF95_01_0002,

Hide Display 52618 66.INSTALL FRONT BUMPER LOWER ABSORBER

for SFTM Made: Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for SFTM Made)>REASSEMBLY202111,999999,_59,_111849,_0500095,RM100000001Z1C3_01_0386,

for GTMC Made: Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for GTMC Made)>REASSEMBLY202203,999999,_59,_111849,_0524334,RM1000000022091_01_0386,

Hide Display 67.INSTALL FRONT BUMPER ASSEMBLY

for SFTM Made: Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for SFTM Made)>INSTALLATION202303,999999,_59,_111849,_0500095,RM100000002AYNL,

for GTMC Made: Click hereVehicle Exterior>EXTERIOR PANELS / TRIM>FRONT BUMPER (for GTMC Made)>INSTALLATION202303,999999,_59,_111849,_0524334,RM100000002AYND,

Hide Display 58166A 68.INSTALL FRONT FLOOR COVER LH

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL TANK>INSTALLATION202203,999999,_51,_111793,_0504184,RM1000000022AQP_01_0100,

Hide Display 58165C 69.INSTALL FRONT FLOOR COVER RH

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (FUEL)>FUEL TANK>INSTALLATION202203,999999,_51,_111793,_0504184,RM1000000022AQP_01_0102,

Hide Display 53737B 70.INSTALL FRONT FENDER APRON SEAL LH

Install the front fender apron seal LH with the 2 bolts and clip.

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

Hide Display 53736 71.INSTALL FRONT FENDER APRON SEAL RH

Install the front fender apron seal RH with the 2 bolts and clip.

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

Hide Display 51420 72.INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

Install the No. 2 engine under cover assembly with the 2 bolts, 2 screws and 6 clips.

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

Hide Display 51441 73.INSTALL NO. 1 ENGINE UNDER COVER

Install the No. 1 engine under cover with the 2 bolts and 6 screws.

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

Hide Display 53896B 74.INSTALL FRONT FENDER FRONT SPLASH SHIELD LH

Install the front fender front splash shield LH with the 3 screws.

Hide Display 53895B 75.INSTALL FRONT FENDER FRONT SPLASH SHIELD RH

Install the front fender front splash shield RH with the 3 screws.

Hide Display 76.INSTALL FRONT WHEELS

Click hereGeneral>MAINTENANCE>TIRE AND WHEEL>INSTALLATION202111,999999,_V1,_112220,_0502516,RM100000001ZAD3_01_0001,

Hide Display 77. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

Hide Display 78.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Click hereSuspension>ALIGNMENT / HANDLING DIAGNOSIS>FRONT WHEEL ALIGNMENT>ADJUSTMENT202111,999999,_53,_111813,_0503137,RM100000001ZDJY,

Hide Display 79.PERFORM INITIALIZATION

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE CONTROL)>THROTTLE BODY>INSTALLATION202111,999999,_51,_111785,_0503267,RM100000001ZE12_01_0035,

Hide Display 80.INSPECT IGNITION TIMING

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE>ON-VEHICLE INSPECTION202111,999999,_51,_111786,_0499716,RM100000001YZHY_01_0008,

Hide Display 81.INSPECT ENGINE IDLE SPEED

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE>ON-VEHICLE INSPECTION202111,999999,_51,_111786,_0499716,RM100000001YZHY_01_0016,

Hide Display 82.INSPECT CO/HC

Click hereEngine / Hybrid System>M20C-FKS, M20D-FKS (ENGINE MECHANICAL)>ENGINE>ON-VEHICLE INSPECTION202111,999999,_51,_111786,_0499716,RM100000001YZHY_01_0011,

Hide Display 83.CHECK SPEED SENSOR SIGNAL

Click hereBrake>BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS>ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for Gasoline Model)>SIGNAL CHECK202111,999999,_54,_111814,_0503031,RM100000001ZCWS,

Hide Display 84. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL

Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>WORK PROCEDURE202406,999999,_V1,_111780,_0504976,RM100000002MNUE,

HINT:: When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.; Click hereGeneral>SETUP>WHEN DISCONNECTING OR RECONNECTING BATTERY TERMINAL>AUTOMATIC LEARNING CHART202111,999999,_V1,_111780,_0504976,RM100000001ZKRU,