Installation
POWER STEERING: STEERING GEAR: INSTALLATION
1. INSTALL TIE ROD ASSEMBLY LH
(a) Install the lock nut and the tie rod assembly LH to the steering rack end sub-assembly until the matchmarks are aligned.
HINT
After adjusting toe-in, torque the lock nut.
2. INSTALL TIE ROD ASSEMBLY RH
HINT
Perform the same procedure as for the LH side.
3. INSTALL POWER STEERING LINK ASSEMBLY
(a) Install the power steering link assembly with the 2 bolts and 2 nuts.
Torque : 70 Nm (713 kgf-cm, 51 ft-lbf)
NOTICE:
* Make sure to tighten the bolts starting from the left side of the vehicle.
* Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.
4. INSTALL FRONT STABILIZER BAR Installation
5. INSTALL FRONT NO. 1 STABILIZER BRACKET LH Installation
6. INSTALL FRONT NO. 1 STABILIZER BRACKET RH Installation
7. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE Installation
8. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
(a) Align the matchmarks on the steering intermediate shaft assembly and the power steering link assembly.
(b) Install the bolt.
Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)
9. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
10. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
HINT
Perform the same procedure as for the LH side.
11. INSTALL FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER LH Installation
12. INSTALL FRONT NO. 1 SUSPENSION ARM SUB-ASSEMBLY LOWER RH
HINT
Perform the same procedure as for the LH side.
13. CONNECT TIE ROD ASSEMBLY LH
(a) Connect the tie rod assembly LH to the steering knuckle with the nut.
Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)
(b) Install a new cotter pin.
NOTICE:
Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.
14. CONNECT TIE ROD ASSEMBLY RH
HINT
Perform the same procedure as for the LH side.
15. INSTALL FRONT SPEED SENSOR LH Installation
16. INSTALL FRONT SPEED SENSOR RH
HINT
Perform the same procedure as for the LH side.
17. INSTALL FRONT AXLE SHAFT NUT LH Installation
18. INSTALL FRONT AXLE SHAFT NUT RH
HINT
Perform the same procedure as for the LH side.
19. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
20. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT
Perform the same procedure as for the LH side.
21. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY Installation
22. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
23. CONNECT ENGINE WIRE Installation
24. INSTALL LOWER INSTRUMENT PANEL SUB-ASSEMBLY Installation
25. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation
26. INSTALL COWL SIDE TRIM SUB-ASSEMBLY RH Installation
27. INSTALL FRONT DOOR SCUFF PLATE RH Installation
28. CONNECT WATER HOSE Installation
29. CONNECT INLET OIL COOLER TUBE SUB-ASSEMBLY Installation
30. CONNECT OUTLET OIL COOLER TUBE SUB-ASSEMBLY Installation
31. CONNECT INLET RADIATOR HOSE Installation
32. CONNECT OUTLET RADIATOR HOSE Installation
33. CONNECT INLET HEATER WATER HOSE Installation
34. CONNECT OUTLET HEATER WATER HOSE Installation
35. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY Installation
36. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY Installation
37. INSTALL NO. 1 INVERTER BRACKET Installation
38. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY Installation
39. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH
40. INSTALL ENGINE MOUNTING CONTROL BRACKET Installation
41. INSTALL ENGINE MOVING CONTROL ROD Installation
42. INSTALL NO. 2 ENGINE MOUNTING STAY RH Installation
43. INSTALL AIR CLEANER BRACKET Installation
44. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY Installation
45. INSTALL INVERTER WITH CONVERTER ASSEMBLY Installation
46. INSTALL NO. 4 INVERTER BRACKET Installation
47. INSTALL ENGINE ROOM RELAY BLOCK ASSEMBLY Installation
48. REMOVE INVERTER COVER Installation
49. CONNECT NO. 3 FRAME WIRE Installation
50. CONNECT MG ECU CONNECTOR Installation
51. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR Installation
52. CONNECT NO. 4 ENGINE WIRE Installation
53. CHECK HIGH VOLTAGE CABLE CONNECTION Installation
54. INSTALL INVERTER COVER Installation
55. CONNECT WATER HOSE Installation
56. INSTALL INVERTER RESERVE TANK SUB-ASSEMBLY Installation
57. CONNECT NO. 2 ENGINE ROOM WIRE Installation
58. CONNECT NO. 1 CIRCUIT BREAKER SENSOR Installation
59. INSTALL AIR CLEANER CASE SUB-ASSEMBLY Installation
60. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
61. INSTALL BATTERY CARRIER SUB-ASSEMBLY Installation
62. INSTALL SERVICE PLUG GRIP Installation
63. INSTALL BATTERY Installation
64. INSTALL FRONT WHEELS
Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)
65. ADD AND INSPECT HYBRID TRANSAXLE FLUID P310 Hybrid Transaxle
66. ADD ENGINE OIL
67. INSPECT FOR FUEL LEAK Testing and Inspection
68. ADD COOLANT (for Inverter) Service and Repair
69. ADD COOLANT (for Engine) Service and Repair
70. INSPECT FOR OIL LEAK
71. INSPECT FOR COOLANT LEAK (for Inverter) Testing and Inspection
72. INSPECT FOR COOLANT LEAK (for Engine) Testing and Inspection
73. INSPECT FOR EXHAUST GAS LEAK Installation
74. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
75. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
HINT
Service and Repair
76. INSTALL NO. 2 ENGINE UNDER COVER Installation
77. INSTALL FRONT FENDER APRON SEAL LH Installation
78. INSTALL FRONT FENDER APRON SEAL RH Installation
79. INSTALL FRONT FENDER LINER LH Installation
80. INSTALL FRONT FENDER LINER RH Installation
81. INSTALL NO. 1 ENGINE UNDER COVER Installation
82. INSPECT STEERING WHEEL CENTER POINT
83. INSPECT IGNITION TIMING Engine
84. INSPECT ENGINE IDLE SPEED Engine
85. INSPECT CO/HC Engine
86. CHECK ABS SPEED SENSOR SIGNAL
HINT
Test Mode Procedure
87. INSTALL NO. 2 ENGINE ROOM SIDE COVER LH Installation
88. INSTALL COOL AIR INTAKE DUCT SEAL Installation
89. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation
90. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
91. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation
92. INSTALL HOOD TO COWL TOP SEAL Installation
93. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
94. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation