M20C-FKS ENGINE MECHANICAL  ENGINE ASSEMBLY  INSTALLATION  

12372A 1.INSTALL ENGINE MOUNTING INSULATOR LH

HINT:

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

a.

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 with the 4 bolts.

Torque:

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

NOTICE:

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

12341 2.INSTALL ENGINE MOUNTING SPACER

HINT:

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

a.

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 install the bolt (A), and then tighten the 2 bolts in the order of (B) and (A).

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.

a.

2.563,0.167 2.719,0.365 0.156,0.198 10 true C 2.823,1 2.979,1.198 0.156,0.198 10 true B 0.552,1.5 0.708,1.698 0.156,0.198 10 true A

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

b.

Attach the clamp.

c.

Connect the No. 2 ground wire to the engine mounting insulator sub-assembly RH with the bolt.

Torque:

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

d.

2.99,3.073 3.146,3.271 0.156,0.198 10 true 1 3.188,1.24 3.344,1.438 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)

e.

Attach the 2 wire harness clamps.

f.

2.115,1.531 2.115,1.271 true 1.823,0.813 1.979,0.458 1.979,0.458 2.167,0.458 true 2.042,1.542 2.24,1.75 0.198,0.208 10 true *1 2.177,0.354 2.396,0.563 0.219,0.208 10 true *2

*1	Suction Pipe Sub-assembly
*2	Air Conditioning Tube And Accessory Assembly

Attach the clamps to connect the suction pipe sub-assembly and air conditioning tube and accessory assembly.

g.

Connect the No. 6 water by-pass hose.

h.

Attach the clamp.

4.INSTALL ENGINE HANGERS

5.REMOVE ENGINE ASSEMBLY FROM ENGINE STAND

82121 6.INSTALL ENGINE WIRE

19315 7.INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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

30400 9.INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

28100 10.INSTALL STARTER ASSEMBLY

11363A 11.INSTALL FLYWHEEL HOUSING SIDE COVER

12311A 12.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

12371A 13.INSTALL REAR ENGINE MOUNTING INSULATOR

12361 14.INSTALL FRONT ENGINE MOUNTING INSULATOR

51100H 15.INSTALL FRONT ENGINE SUPPORT MEMBER SUB-ASSEMBLY

16.CONNECT WIRE HARNESS

45319 17.INSTALL STEERING GEAR HEAT INSULATOR

16260 18.CONNECT WATER BY-PASS HOSE ASSEMBLY

16261G 19.INSTALL FLOW SHUTTING VALVE (NO. 1 WATER BY-PASS HOSE)

20.CONNECT VACUUM HOSE

a.

for AWD:

i.

Attach the 4 clamps to connect the vacuum hose to the continuously variable transaxle assembly.

b.

for 2WD:

i.

Attach the 6 clamps to connect the vacuum hose to the continuously variable transaxle assembly.

ii.

Connect the vacuum hose to the rear engine mounting insulator.

c.

Connect the vacuum hose to the front engine mounting insulator.

17650H 21.INSTALL VACUUM SWITCHING VALVE (for Active Control Engine Mount System)

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

11361J 23.INSTALL FLYWHEEL HOUSING UNDER COVER

24.REMOVE ENGINE HANGERS

23825 25.INSTALL FUEL DELIVERY GUARD

37117 26.INSTALL PROPELLER SHAFT HEAT INSULATOR (for AWD)

17141 27.INSTALL EXHAUST MANIFOLD

17118 28.INSTALL MANIFOLD STAY

17167 29.INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

25706 30.INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

25760 31.INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY

89481B 32.INSTALL DIFFERENTIAL PRESSURE SENSOR

33.INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

HINT:

Perform inspection after repair after replacing the engine assembly.

Click hereEngine / Hybrid System>M20C-FKS (ENGINE CONTROL)>SFI SYSTEM>INITIALIZATION202304,202405,_51,_087036,_0418131,RM1000000029CMT,202405,999999,_51,_087036,_0418131,RM100000002IF8T,

a.

Set the engine assembly with transaxle on an engine lifter.

0,0 0,0 false

Attachments

-

-

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.

b.

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.

c.

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 engine support member sub-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)

d.

Install the rear front suspension member brace LH and rear front suspension member brace RH to the front engine support member sub-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)

e.

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)

NOTICE:

While holding the bolt in place, tighten the nut.

f.

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)

45220 34.CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

43420G 35.INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

43420 36.INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

43410 37.INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

48069 38.CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

48068 39.CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

45470 40.CONNECT TIE ROD ASSEMBLY LH

45460 41.CONNECT TIE ROD ASSEMBLY RH

48810 42.CONNECT FRONT STABILIZER LINK ASSEMBLY LH

48820B 43.CONNECT FRONT STABILIZER LINK ASSEMBLY RH

44.CONNECT FRONT SPEED SENSOR LH

45.CONNECT FRONT SPEED SENSOR RH

43502H 46.INSTALL FRONT AXLE SHAFT NUT LH

43501H 47.INSTALL FRONT AXLE SHAFT NUT RH

43502H 48.STAKE FRONT AXLE SHAFT NUT LH

43502H 49.STAKE FRONT AXLE SHAFT NUT RH

33820B 50.CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

NOTICE:

Before installing the transmission control cable assembly, check that the shift lever are in N.

a.

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

*a

N

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.

b.

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.

c.

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

37100 51.TEMPORARILY INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for AWD)

37100 52.TIGHTEN PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for AWD)

53.INSPECT AND ADJUST JOINT ANGLE (for AWD)

58152A 54.INSTALL LOWER NO. 1 FRONT FLOOR HEAT INSULATOR (for AWD)

17410 55.INSTALL FRONT EXHAUST PIPE ASSEMBLY

58398F 56.INSTALL NO. 1 FLOOR UNDER COVER

58165C 57.INSTALL FRONT FLOOR COVER RH

58399D 58.INSTALL NO. 2 FLOOR UNDER COVER

58166A 59.INSTALL FRONT FLOOR COVER LH

16281F 60.CONNECT NO. 5 WATER BY-PASS HOSE

61.CONNECT WIRE HARNESS

a.

Connect the wire harness to the vehicle body with the bolt.

Torque:

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

b.

Attach the clamp.

c.

Connect the No. 3 engine wire to the continuously variable transaxle assembly with the bolt.

Torque:

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

d.

Attach the claw to install the wire harness to the engine room relay block and junction block assembly.

e.

Connect the 5 connectors to the engine room relay block and junction block assembly.

f.

Install the nut to the engine room relay block and junction block assembly.

Torque:

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

g.

Attach the 3 claws and install the No. 2 relay block cover to the engine room relay block and junction block assembly.

88711 62.CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE SUB-ASSEMBLY

88704 63.CONNECT SUCTION HOSE SUB-ASSEMBLY

16572D 64.CONNECT NO. 2 RADIATOR HOSE

a.

1.573,3.781 1.042,3.406 true 0.292,2.833 0.604,2.99 0.313,0.156 10 false *a 1.302,2.948 1.615,3.104 0.313,0.156 10 false *b 1.615,3.719 1.927,3.875 0.313,0.156 10 false *c 0.76,2.833 1.073,2.99 0.313,0.156 10 false *d 1.406,3.313 1.719,3.469 0.313,0.156 10 false *e 2.156,4.042 2.469,4.198 0.313,0.156 10 false *f 0.875,1.802 1.135,1.99 0.26,0.188 10 true *a

*a	View A
*b	120°
*c	Paint Mark
*d	Upper Side
*e	RH Side
*f	2 to 5 mm (0.0787 to 0.197 in.)

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

NOTICE:

·

Align the direction of the claw on the clip with the paint mark on the hose.

·

Make sure the No. 2 radiator hose is securely inserted to the stopper.

b.

Connect the No. 2 radiator hose to the fan with motor assembly with the clamp.

16571C 65.CONNECT NO. 1 RADIATOR HOSE

a.

1.573,3.719 1.042,3.344 true 0.302,2.719 0.615,2.875 0.313,0.156 10 false *a 1.323,2.99 1.635,3.146 0.313,0.156 10 false *b 1.635,3.625 1.948,3.781 0.313,0.156 10 false *c 0.885,2.833 1.198,2.99 0.313,0.156 10 false *d 0.406,3.448 0.719,3.604 0.313,0.156 10 false *e 2.146,4.104 2.458,4.26 0.313,0.156 10 false *f 0.854,1.313 1.031,1.521 0.177,0.208 10 true *a

*a	View A
*b	120°
*c	Paint Mark
*d	Upper Side
*e	RH Side
*f	2 to 7 mm (0.0787 to 0.276 in.)

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

NOTICE:

·

Align the direction of the claw on the clip with the paint mark on the hose.

·

Make sure the No. 1 radiator hose is securely inserted to the stopper.

b.

Connect the No. 1 radiator hose to the No. 1 radiator bracket with the clamp.

23901 66.CONNECT FUEL TUBE SUB-ASSEMBLY

87245 67.CONNECT INLET HEATER WATER HOSE

a.

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 securely insert the inlet heater water hose connector to the stopper of the pipe.

b.

0.74,1.417 0.979,1.417 0.979,1.417 1.313,1.531 true 0.542,1.313 0.74,1.531 0.198,0.219 10 true *a

*a	Retainer
	Push
	Push in

Push in the retainer.

c.

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

87246 68.CONNECT OUTLET HEATER HOSE

a.

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 securely insert the outlet heater water hose connector to the stopper of the pipe.

b.

0.885,1.49 1.115,1.49 1.115,1.49 1.521,1.646 true 0.688,1.375 0.885,1.583 0.198,0.208 10 true *a

*a	Retainer
	Push
	Push in

Push in the retainer.

c.

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

44773F 69.CONNECT NO. 1 VACUUM HOSE CONNECTOR

23820 70.CONNECT NO. 1 FUEL VAPOR FEED HOSE

74404B 71.INSTALL BATTERY CLAMP SUB-ASSEMBLY

a.

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

Torque:

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

b.

Attach the 4 clamps to the battery clamp sub-assembly.

c.

0.427,1.448 0.573,1.448 0.573,1.448 0.677,1.708 false 0.615,0.781 0.75,0.781 0.75,0.781 0.958,1.094 false 1.396,0.906 1.573,0.583 1.573,0.583 1.729,0.583 false 1.74,0.479 1.948,0.667 0.208,0.188 10 false *1 0.427,0.688 0.625,0.906 0.198,0.219 10 false *2 0.25,1.354 0.448,1.552 0.198,0.198 10 false *3

*1	Engine Room Main Wire
*2	No. 2 Engine Wire
*3	Positive (+) Battery Terminal

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

d.

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)

e.

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

72.INSTALL BATTERY

89661 73.INSTALL ECM

74.INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

17751 75.INSTALL NO. 1 INLET AIR CLEANER

12601B 76.INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

77.INSPECT VACUUM HOSES

a.

Check that the vacuum hose is installed as shown in the illustration.

0.063,0.031 0.344,0.26 0.281,0.229 10 true *A 3.875,0.052 4.135,0.302 0.26,0.25 10 true *B

*A

for 2WD

*B

for AWD

78.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

79. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL

80.INSPECT SHIFT LEVER POSITION

81.ADJUST SHIFT LEVER POSITION

82.CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

83.ADD ENGINE OIL

84.ADD TRANSFER OIL (for AWD)

85.ADD ENGINE COOLANT

86.ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID

87.INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK

88. WARM UP ENGINE

89.INSPECT FOR ENGINE OIL LEAK

90.INSPECT FOR COOLANT LEAK

91.INSPECT FOR REFRIGERANT LEAK

92.INSPECT FOR FUEL LEAK

93.INSPECT FOR EXHAUST GAS LEAK

94.CHECK ENGINE OIL LEVEL

95.INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

52618 96.INSTALL FRONT LOWER BUMPER ABSORBER

97.INSTALL FRONT BUMPER ASSEMBLY

53737D 98.INSTALL FRONT FENDER APRON SEAL LH

a.

2.719,1.354 2.875,1.552 0.156,0.198 10 false .

	Bolt
	Clip

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

Torque:

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

53736E 99.INSTALL FRONT FENDER APRON SEAL RH

a.

2.99,1.042 3.146,1.24 0.156,0.198 10 false .

	Bolt
	Clip

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

Torque:

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

51420 100.INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY

a.

0,0 0,0 false

	Bolt
	Screw
	Clip

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)

51441 101.INSTALL NO. 1 ENGINE UNDER COVER

a.

Attach the guide to install the No. 1 engine under cover.

b.

Install the 2 bolts and 8 screws.

Torque:

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

0,0 0,0 false

Bolt

Screw

53896B 102.INSTALL FRONT FENDER FRONT SPLASH SHIELD LH

a.

Attach the clip to install the front fender front splash shield LH.

b.

Install the 4 screws.

53895B 103.INSTALL FRONT FENDER FRONT SPLASH SHIELD RH

a.

Attach the clip to install the front fender front splash shield RH.

b.

Install the 4 screws.

104.INSTALL FRONT WHEELS

105. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

106.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

107.PERFORM INITIALIZATION

108.INSPECT IGNITION TIMING

109.INSPECT ENGINE IDLE SPEED

110.INSPECT CO/HC

111.CHECK SPEED SENSOR SIGNAL