Engine installation (RZ4E-TC)

1. Engine installation

1) Install the engine to the vehicle using a hoist.

Note

  • Slowly operate to move the engine to the installation position.
  • Slowly operate the hoist so that the transmission side is low, while pulling to the rear of the engine.

2) Connect the engine foot to engine mounting.

Note

  • Tighten the engine mounting fixing bolts from above the engine using an extension bar that is 600 mm {23.6 in} or longer.

Caution

  • Tighten bolts while the engine foot is securely seated on the engine mounting to prevent bolts from loosening.

Tightening torque: 131 N・m { 13.4 kgf・m / 97 lb・ft }

Legend

  1. Engine foot
  2. Engine mounting

3) Remove the wire from the engine hanger and hoist.

4) Remove special tool from the flywheel housing.

5) Remove the special tool from the generator bracket.

2. Fuel hose connect

1) Connect the fuel return hose to the fuel leak-off pipe.

2) Connect the fuel feed hose to the fuel supply pump.

Legend

  1. Fuel return hose
  2. Fuel feed hose

3. Clutch installation

Refer to "5.Transmission, Transaxle 5E.Clutch System(MVL) Clutch installation".

4. Transmission installation

Refer to "5.Transmission, Transaxle 5B.Automatic(AWR6B45) transmission installation".

5. Radiator lower hose connect

1) Connect the radiator lower hose to the water intake pipe.

Note

  • Insert the lower hose until it makes full contact with the pipe.
  • Soapy water can be applied when installing the lower hose.

Legend

  1. Clamp
  2. Arrow mark
  3. Radiator lower hose

Note

  • Align the clamp with the lower hose arrow mark end to install.

Legend

  1. Clamp
  2. Arrow mark
  3. Radiator lower hose

Note

  • Install the clamp in the direction shown in the following diagram.
  • The diagram about the clamp direction shows the state viewed from the vehicle front.

6. Catalytic converter installation

Refer to "1.Engine 1G.Exhaust(RZ4E-TC) catalytic converter installation".

7. Vacuum hose connect

1) Connect the vacuum hose to the vacuum pipe.

8. ECM connect

1) Connect the harness to the frame.

2) Pull in the harness toward inside the room.

3) Connect the connector to the ECM.

9. Instrument panel passenger-side lower cover installation

1) Connect the connector to the instrument panel passenger-side lower cover.

2) Install the instrument panel passenger-side lower cover to the instrument panel.

RHD

Legend

  1. Instrument panel passenger-side lower cover
  2. Clip

LHD

Legend

  1. Instrument panel passenger-side lower cover
  2. Clip

10. Glove box installation

1) Install the glove box to the instrument panel.

RHD

Legend

  1. Glove box

LHD

Legend

  1. Glove box

11. Cooling fan installation

1) Install the cooling fan clutch and cooling fan as a set to the water pump.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

12. A/C compressor connect

1) Connect the A/C compressor to the generator bracket.

Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }

2) Connect the pipe clip to the air duct bracket.

13. Generator installation

1) Install the generator to the generator bracket.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

2) Connect the B-terminal to the generator.

Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・in }

3) Connect the connector to the generator.

14. Power steering oil pump connect

1) Connect the power steering oil pump to the generator bracket.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

2) Install the power steering oil pump pulley to the power steering oil pump.

Note

  • Secure the M10 x 1.5 bolt with a tool, and tighten the pulley mounting bolt.

Tightening torque: 29 N・m { 3.0 kgf・m / 21 lb・ft }

3) Remove the bolt and nut from the power steering oil pump shaft.

15. Freezer compressor installation

1. Freezer specifications

1) Install the freezer compressor bracket to the cylinder block.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

2) Install the tension pulley to the freezer compressor bracket.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

3) Install the freezer compressor to the freezer compressor bracket.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

16. Cooling fan belt installation

Refer to "1.Engine 1D.Cooling(RZ4E-TC) cooling fan belt installation".

17. Fan guide installation

1) Install the fan guide to the radiator.

Tightening torque: 6.5 N・m { 0.7 kgf・m / 58 lb・in }

2) Install the fan shroud to the fan guide.

Legend

  1. Fan shroud
  2. Fan guide
  3. Radiator

18. Radiator reserve tank installation

1) Clean the radiator reserve tank using detergent.

Note

  • Wash with clean water, and drain the water.

2) Assemble the reserve tank hose to the radiator reserve tank.

Caution

  • Assemble the reserve tank hose to the dent to fit the radiator reserve tank shape.

Legend

  1. Radiator reserve tank
  2. Reserve tank hose

3) Install the radiator reserve tank to the fan guide.

Tightening torque: 8.4 N・m { 0.9 kgf・m / 74 lb・in }

4) Connect the radiator reserve tank hose to the radiator.

19. Radiator upper hose installation

1) Install the radiator upper hose and clamp to the water outlet pipe and radiator.

Note

  • Align the painted arrow on the upper hose with the pipe boss section to install.
  • Insert the upper hose until it makes full contact with the pipe.
  • Soapy water can be applied when installing the upper hose.

Legend

  1. Radiator upper hose
  2. Boss section
  3. Clamp
  4. Arrow mark

Note

  • Align the clamp with the upper hose arrow mark end to install.

Legend

  1. Clamp
  2. Arrow mark

Note

  • Install the clamp in the direction shown in the following diagram.
  • The diagram about the clamp direction shows the state viewed from the vehicle front.

20. Fuse box connect

1) Connect the battery harness to the fuse box.

2) Connect the engine harness to the fuse box.

3) Install the fuse box cover to the fuse box.

21. Battery installation

1) Install the battery to vehicle.

2) Install the battery bracket to the frame.

Tightening torque: 4.0 N・m { 0.41 kgf・m / 35.4 lb・in } Battery side

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft } Frame side

3) Connect the battery cable to the battery.

4) Connect the battery ground cable to the frame.

Legend

  1. Battery cable
  2. Battery bracket
  3. Battery ground cable

22. Air cleaner installation

1) Install the air cleaner to the vehicle.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

Legend

  1. Air cleaner
  2. MAF and IAT sensor
  3. Barometric pressure sensor

2) Connect the connector to the barometric pressure sensor.

3) Connect the connector to the MAF and IAT sensor.

23. Air intake hose installation

1) Install the air intake hose to the intake air duct and intercooler.

Caution

  • Align the marks on the pipe side and hose side.

Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in }

Legend

  1. Intercooler
  2. Air intake hose
  3. Intake air duct
  4. Clamp

24. Intake hose installation

1) Install the intake hose to the turbocharger and air pipe.

Caution

  • Align the marks on the pipe side and hose side.

Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in } Clamp

Legend

  1. Turbocharger
  2. Intercooler
  3. Intake hose
  4. Clamp

25. Air duct installation

1) Align the air duct with the air cleaner and turbocharger.

Legend

  1. Air duct

2) Referring to the diagram, align the alignment mark positions and connect the air duct to the turbocharger.

Tightening torque: 4.0 N・m { 0.4 kgf・m / 35 lb・in }

Legend

  1. Alignment mark

3) Install the PCV hose to the cylinder head cover and air duct.

Caution

  • Align the marks on the pipe side and hose side.

Legend

  1. PCV hose
  2. Clamp

4) Install the intake air duct to the air cleaner and radiator core support.

Legend

  1. Intake air duct
  2. Clip

26. Underguard installation

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard installation".

27. Preliminary and post procedures

1. Post procedures

1) Lower the vehicle.

2) Connect the battery cable to the battery negative terminal.

3) Referring to the following, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function.

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

4) Close the engine hood.

28. Coolant filling

1) Fill with engine coolant up to the radiator filler neck.

Note

  • Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

Caution

  • Fill slowly to prevent air from entering the system.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator with engine coolant.

Note

  • Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant lowers.

Caution

  • Repeat the operation until the coolant level no longer drops.

3) Add engine coolant up to the MAX line of the radiator reserve tank.

Legend

  1. Radiator reserve tank
  2. MAX line
  3. MIN line

4) Install the radiator cap to the radiator.

5) Start and idle the engine.

Caution

  • Idle the engine for 5 minutes or more.

6) Stop the engine.

7) Remove the radiator cap from the radiator.

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

8) Fill with engine coolant up to the radiator filler neck.

Note

  • If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.

9) Install the radiator cap to the radiator.

10) Start the engine.

11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

Note

  • Touch the radiator upper hose, and confirm that it has become warm.
  • If it has not become warm, go back to Step 11.

Caution

  • Do not try determining it by using only an engine coolant temperature gauge.

13) Idle the engine for 5 minutes.

14) Stop the engine.

15) Remove the radiator cap from the radiator.

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
  • When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.

16) Fill with engine coolant up to the radiator filler neck.

Note

  • Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

17) Add engine coolant up to the MAX line of the radiator reserve tank.

18) Install the radiator cap to the radiator.

19) Repeat steps 10 to 18 until the coolant level no longer lowers.

Caution

  • If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.

29. Fuel air bleed

1) Open the engine hood.

2) Press the priming pump until it becomes hard.

Caution

  • Completely bleed air, as insufficient air bleeding may lead to engine malfunctions.

Legend

  1. Priming pump
  2. Fuel filter with sedimenter

30. Freezer compressor drive belt adjustment

1. Freezer specifications

When installing a new belt, initial stretching of the belt occurs.
In addition, when reusing the belt, the belt needs to be fitted to the pulley groove.
After fitting the freezer compressor drive belt, adjust the tension of the freezer compressor drive belt again.

1) Loosen the tension pulley lock nut.

2) Turn the tension pulley adjust bolt to adjust the tension.

Note

  • The standard deflection shown is the value obtained when the specified load is applied to the measurement point of the freezer compressor drive belt.

Standard: 98 N { 10 kg / 22 lb } Load

Caution

  • Accurately adjust the tension as there is a possibility the service life of the belt may be shortened or belt squeal may be generated if the tension is not within the appropriate range.
  • Use a sonic tension meter to verify accurate tension adjustment.
Measurement point 1

When new
 Reused
Tension
 541 to 721 N { 55 to 74 kg / 122 to 162 lb }
 379 to 505 N { 39 to 51 kg / 85 to 114 lb }
Vibration frequency
 181 to 209 Hz
 152 to 175 Hz
Deflection
 5.3 to 6.7 mm { 0.209 to 0.264 in }
 6.5 to 8.1 mm { 0.256 to 0.319 in }
Measurement point 2

When new
 Reused
Tension
 541 to 721 N { 55 to 74 kg / 122 to 162 lb }
 379 to 505 N { 39 to 51 kg / 85 to 114 lb }
Vibration frequency
 150 to 173 Hz
 125 to 144 Hz
Deflection
 6.4 to 8.0 mm { 0.252 to 0.315 in }
 8.4 to 10.0 mm { 0.331 to 0.394 in }

Legend

  1. Tension pulley adjust bolt
  2. Tension pulley lock nut
  3. Freezer compressor drive belt
  4. Measurement position 1
  5. Measurement position 2

3) Tighten the tension pulley lock nut to the specified torque.

Tightening torque: 41 N・m { 4.2 kgf・m / 30 lb・ft }

31. ECM setting

If the engine has been replaced, perform Injector ID Code programming, ECM learned value clear, and fuel supply pump relearning.

1. Injector ID Code programming

Check the label attached to the engine cover at the time of factory shipment or the housing of each injector for the Injector ID Code.

Label on the cylinder head cover (Sample)

Legend

  1. No. 1 cylinder Injector ID Code
  2. No. 2 cylinder Injector ID Code
  3. No. 3 cylinder Injector ID Code
  4. No. 4 cylinder Injector ID Code
  5. Injector ID Code label

The correct order of the ID codes shown in the following injector illustration is as follows.
95 04 F9 F8 F0 00 F0 E7 09 F6 F9 96

Injector (Sample)

Legend

  1. Injector ID Code
  2. Injector

1) Connect the scan tool to the DLC.

2) Turn ON the ignition switch.

3) Select the scan tool item.

  • Diagnostics > Engine > RZ4E > Programming > Injector ID Code > Program Injector ID Code

4) Program the Injector ID Code into the ECM by following the on-screen instructions.

5) After the programming is completed, turn the ignition switch OFF for 30 seconds.

2. ECM learned value clear

1) Connect the scan tool to the DLC.

2) Turn ON the ignition switch.

3) Select the scan tool item.

  • Diagnostics > Engine > RZ4E > Special Function > Reset Small Fuel Injection Quantity Learning

4) Perform the ECM learned value clear by following the on-screen instructions.

5) After the learned value clear is complete, turn OFF the ignition switch for 30 seconds.

3. Fuel Supply Pump Relearning

1) Connect the scan tool to the DLC.

2) Turn ON the ignition switch.

3) Select the scan tool item.

  • Diagnostics > Engine > RZ4E > Special Function > Fuel Supply Pump Learn Resetting

4) Reset the Fuel Supply Pump Learning by following the on-screen instructions.

5) Turn OFF the ignition switch for 30 seconds.

6) Start and idle the engine until the engine coolant temperature reaches 65°C {149°F} or more.

7) Observe the Fuel Supply Pump Learning Status parameter on the scan tool.

8) The procedure is complete when the parameter changes from Not Learned to Learned.

32. Engine vehicle inspection

1. Inspection before starting the engine

1) Inspect for the following.

  • Engine oil level
  • Engine coolant level
  • Items around the engine that may get caught

2. Inspection after starting the engine

1) Inspect for the following.

  • Abnormal noise
  • Abnormal vibration
  • Fuel leakage
  • Oil leakage
  • Water leakage
  • Air leakage
  • Exhaust gas leakage
  • Exhaust gas color

3. Inspection after stopping the engine

1) Inspect for the following.

  • Engine oil level
  • Engine coolant level
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