RX400h · Service Manual ENGINE

INSTALLATION

Removal / installation


1. INSTALL OIL PUMP SEAL

  1. A078754E01
    Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
    SST
    09223-00010  

    NOTICE:
    1. Do not tap the oil seal at an angle.
    2. Keep the lip free from foreign objects.

  1. Apply MP grease to the oil seal lip.


2. INSTALL OIL PUMP ASSEMBLY

  1. Remove any old seal packing material from the contact surface.

  1. A036784
    Apply a light coat of engine oil to a new O-ring and place it on the cylinder block.

  1. A078725E01
    Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 in.)) as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Apply seal packing to the inner side of the bolt holes.
    3. Install the oil pump within 3 minutes after applying seal packing.
    4. Do not expose the seal to engine oil within 2 hours after installing.

  1. A036785
    Align the key of the oil pump drive gear with the keyway located on the crankshaft, and slide the oil pump into place.

  1. A051990E01
    Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.

    Torque:
    Bolt A:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }
    Bolt B:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }
    Bolt C:
    43 N*m{ 439 kgf*cm , 32 ft.*lbf }


3. INSTALL CRANK POSITION SENSOR

Torque:
8.0 N*m{ 80 kgf*cm , 71 in.*lbf }


4. INSTALL OIL PAN SUB-ASSEMBLY

  1. Remove any old seal packing from the contact surface.

  1. A078726E01
    Apply a continuous bead of seal packing (Diameter 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Apply seal packing to the outer side of the bolt holes in the region "X".
    3. Apply seal packing to the inner side of the bolt holes in the region "Y".
    4. Install the oil pan within 3 minutes after applying seal packing.
    5. Do not expose the seal to engine oil within 2 hours after installing.

  1. A108539E01
    Install oil pan sub-assembly with the 17 bolts. Tighten the bolts uniformly in several steps.

    Torque:
    10 mm Bolt A:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }
    12 mm Bolt B:
    20 N*m{ 199 kgf*cm , 14 ft.*lbf }


5. INSTALL OIL STRAINER SUB-ASSEMBLY

  1. A108540
    Install a new gasket and the oil strainer with the bolt and 2 nuts.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }


6. INSTALL OIL PAN SUB-ASSEMBLY NO.2

  1. Remove any old seal packing from the contact surface.

  1. A078727E01
    Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.16 to 0.20 in.)) as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Apply seal packing to the inner side of the bolt holes.
    3. Install the oil pan within 3 minutes after applying seal packing.
    4. Do not expose the seal to engine oil within 2 hours after installing.

  1. A036750
    Install oil pan No.2 with the 10 bolts and 2 nuts.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }


7. INSTALL CRANKSHAFT TIMING PULLEY

  1. A078746E01
    Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.

    NOTICE:
    Do not scratch the sensor area of the crankshaft timing pulley.

  1. Install the timing belt plate with the bolt.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }


8. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.1

  1. Using a socket hexagon wrench 10 mm, install the plate washer and timing belt idler No.1 with the pivot bolt.

    Torque:
    34 N*m{ 347 kgf*cm , 25 ft.*lbf }


9. INSTALL TIMING BELT

  1. Remove any oil or water on the pulleys, and keep them clean.

    NOTICE:
    1. If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
    2. Wipe only the pulleys; do not use any cleaning agent.

  1. Inspect the idler pulleys.

    1. Check that the idler pulley turns smoothly.

    2. Visually check the seal portion of the idler pulley for oil leakage.

  1. Inspect the water pump.

    1. Turn the pulley, and check that the water pump bearing moves smoothly and does not make any noise.

    2. Visually check the drain hole for coolant leakage.

  1. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.

  1. A082349E01
    Turn the crankshaft counterclockwise by approximately 60°.

    NOTICE:
    To prevent contacting the piston head and the valve head, set the crankshaft pulley at 60° BTDC/compression position.

  1. A078751E01
    Using SST, turn the timing pulleys, and align the timing marks of the timing pulleys with the No.3 timing belt cover.
    SST
    09960-10010   (09962-01000, 09963-01000)

    NOTICE:
    Be sure to hold the SST with the timing marks aligned to prevent the left bank pulley from deviating to the right.

  1. A005062E01
    Turn the crankshaft, and align the timing mark of the crankshaft timing pulley with the oil pump body.

  1. A052840E01
    Face the front mark on the timing belt forward.

  1. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.

  1. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.

  1. A078702E02
    Install the timing belt in the following order.
    1st
    		 Crankshaft timing pulley
    2nd
    		 Water pump pulley
    3rd
    		 LH camshaft timing pulley
    4th
    		 No.2 idler pulley
    5th
    		 RH camshaft timing pulley
    6th
    		 No.1 idler pulley

    NOTICE:
    Be sure to hold the SST with the timing marks aligned to prevent the left bank pulley from deviating to the right.


10. INSTALL CHAIN TENSIONER ASSEMBLY NO.1

  1. Set the timing belt tensioner upright on the press.

  1. A036238E01
    Slowly press in the push rod.

    NOTICE:
    Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod.

  1. Align the holes of the push rod and housing, and pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.

  1. Release the press.

  1. Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.

    Torque:
    27 N*m{ 280 kgf*cm , 20 ft.*lbf }

    NOTICE:
    Be sure to tighten the bolts equally. Installing the tensioner at an angle may cause improper operation.

  1. Remove the 1.5 mm hexagon wrench from the tensioner.

  1. A078326E01
    Turn the crankshaft 2 revolutions slowly and align the timing mark of the crankshaft timing pulley with the oil pump body.

    NOTICE:
    Always turn the crankshaft clockwise.

  1. A005052E01
    Check the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No.3 timing belt cover as shown in the illustration.
    If the marks do not align, remove the timing belt and reinstall it.

  1. Remove the crankshaft pulley bolt.


11. INSTALL TIMING BELT GUIDE NO.2

  1. A036239E01
    Install the timing belt guide with the cup side facing toward the engine front.


12. INSTALL ENGINE MOUNTING BRACKET RH

  1. A108728
    Install the engine mounting bracket RH with the 2 bolts and 2 nuts.

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }


13. INSTALL TIMING BELT NO.2 COVER

  1. Visually check for cracks and breaks on the gasket of the timing belt cover.
    If a trace of water is found in the visual check, replace the timing belt cover.

  1. A108158E01
    Install the timing belt cover with the 5 bolts.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

  1. Connect the 2 clamps.


14. INSTALL TIMING BELT NO.1 COVER

  1. Visually check for cracks and breaks on the gasket of the timing belt cover.
    If a trace of water is found in the visual check, replace the timing belt cover.

  1. Install the timing belt cover.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

  1. Install the engine wire protector cover to the timing belt No.3 cover.


15. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY

  1. Install the oil level gage sub-assembly.


16. INSTALL COMPRESSOR MOUNTING BRACKET NO.1

  1. Temporarily install the mounting bracket with the 4 bolts.

  1. A109435E01
    Install the mounting bracket by tightening the 4 bolts in the order shown in the illustration.


17. INSTALL ENGINE MOUNTING STAY BRACKET

  1. A109434
    Install the 3 bolts, nut and engine mounting stay bracket.

    Torque:
    52 N*m{ 530 kgf*cm , 38 ft.*lbf }


18. INSTALL ENGINE MOUNTING BRACKET RH

  1. A109433
    Install the 3 bolts and engine mounting bracket RH.

    Torque:
    54 N*m{ 551 kgf*cm , 40 ft.*lbf }


19. INSTALL CRANKSHAFT PULLEY

  1. Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.

  1. A110761E01
    Using SST, install the pulley bolt.
    SST
    09213-54015   (91651-60855)
    09330-00021  

    Torque:
    220 N*m{ 2,243 kgf*cm , 162 ft.*lbf }


20. INSTALL MANIFOLD STAY NO.2

  1. Install the 2 bolts and manifold stay No.2.

    Torque:
    49 N*m{ 500 kgf*cm , 36 ft.*lbf }


21. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2

  1. A108153E01
    Install a new gasket as shown in the illustration.

  1. A078402E02
    Install the exhaust manifold converter No.2 with the 6 nuts and bolt. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.

    Torque:
    49 N*m{ 500 kgf*cm , 36 ft.*lbf }

  1. Retighten nuts 1 and 2 shown in the illustration.


22. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2

  1. A108154
    Install the 2 bolts and exhaust manifold heat insulator No.2.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }


23. INSTALL MANIFOLD CONVERTER INSULATOR NO.3

  1. A108736
    Install the bolt, nut and manifold converter insulator No.3.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }


24. REMOVE ENGINE STAND

25. INSTALL FLYWHEEL SUB-ASSEMBLY

  1. A109809E01
    Using SST, hold the crankshaft.
    SST
    09213-54015   (91651-60855)
    09330-00021  

  1. Clean the bolts and bolt holes.

  1. Apply adhesive to 2 or 3 threads of the bolts.

    Adhesive:
    Part No.08833-00070, THREE BOND 1324 or equivalent

  1. Install the flywheel on the crankshaft.

  1. A108132E01
    Using several steps, install and tighten the 8 bolts uniformly in the sequence shown in the illustration.

    Torque:
    83 N*m{ 846 kgf*cm , 61 ft.*lbf }

    NOTICE:
    Do not start the engine within 1 hour after installing.


26. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY

  1. A109809E01
    Using SST, hold the crankshaft.
    SST
    09213-54015   (91651-60855)
    09330-00021  

  1. A108131
    Install the 6 bolts and transmission input damper.

    Torque:
    30 N*m{ 306 kgf*cm , 22 ft.*lbf }

    HINT:
    Take care not to insert the transmission input damper in the wrong direction.


27. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY

  1. Make sure that the knock pins are installed on the engine.

  1. C105753E01
    Install the hybrid vehicle transaxle and the 8 bolts shown in the illustration to the engine.

    Torque:
    Bolt A:
    64 N*m{ 653 kgf*cm , 47 ft.*lbf }

    Torque:
    Bolt B:
    46 N*m{ 469 kgf*cm , 34 ft.*lbf }

    Torque:
    Bolt C:
    64 N*m{ 653 kgf*cm , 47 ft.*lbf }

    Torque:
    Bolt D:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }

    NOTICE:
    1. Do not reuse bolt B.
    2. Do not forcibly pry out the hybrid vehicle transaxle assembly
    3. Do not apply the grease either to the spline or to the input shaft.

    Bolt
    		 Installation direction
    		 Diameter
    		 Bolt length
    A
    		 From transaxle to engine
    		 12 mm (0.47 in.)
    		 55 mm (2.17 in.)
    B
    		 From engine to transaxle
    		 10 mm (0.39 in.)
    		 55 mm (2.17 in.)
    C
    		 From transaxle to engine
    		 12 mm (0.47 in.)
    		 55 mm (2.17 in.)
    D
    		 From engine to transaxle
    		 10 mm (0.39 in.)
    		 33 mm (1.30 in.)


28. INSTALL ENGINE MOUNTING BRACKET FRONT

  1. C105752
    Install the engine mounting bracket front with the 3 bolts.

    Torque:
    64 N*m{ 653 kgf*cm , 47 ft.*lbf }


29. INSTALL FLYWHEEL HOUSING UNDER COVER

  1. C105748
    Install the flywheel housing under cover with the 2 bolts.

    Torque:
    7.8 N*m{ 80 kgf*cm , 69 in.*lbf }


30. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

  1. Install a new drive shaft hole snap ring.

  1. Coat the spline of the inboard joint shaft assembly with ATF.

  1. C108264
    Align the shaft splines and install the drive shaft assembly with a brass bar and a hammer.

    NOTICE:
    1. Set the snap ring with the opening side facing down.
    2. Be careful not to damage the drive shaft dust cover, boot, or oil seal.


31. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

  1. Coat the spline of the inboard joint shaft assembly with ATF.

  1. Align the shaft splines and install the drive shaft assembly.

    NOTICE:
    Be careful not to damage the drive shaft dust cover, boot, or oil seal.

  1. C108266J01
    Using pliers, install a new bearing bracket hole snap ring.

  1. C108267
    Install a new bolt to the drive shaft bearing bracket.

    Torque:
    32 N*m{ 330 kgf*cm , 24 ft.*lbf }


32. INSTALL FRONT FRAME ASSEMBLY

  1. A078403E01
    Install the engine mounting insulators RH and LH with the 2 nuts.

    Torque:
    95 N*m{ 969 kgf*cm , 70 ft.*lbf }

  1. A108133
    Install the engine mounting insulator FR with the nut.

    Torque:
    87 N*m{ 887 kgf*cm , 64 ft.*lbf }

  1. A108134
    Install the engine mounting insulator RR with the 2 bolts.

    Torque:
    75 N*m{ 765 kgf*cm , 55 ft.*lbf }


33. INSTALL HV TRANSAXLE MASS DAMPER

  1. A109817
    Install the bolt and transaxle mass damper.

    Torque:
    14 N*m{ 138 kgf*cm , 10 ft.*lbf }


34. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

  1. A108151E01
    Install a new gasket as shown in the illustration.

  1. A078400E02
    Install a new gasket and the exhaust manifold RH with the 6 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.

    Torque:
    49 N*m{ 500 kgf*cm , 36 ft.*lbf }

  1. Retighten nuts 1 and 2 shown in the illustration.


35. INSTALL MANIFOLD STAY

  1. Temporarily install the manifold stay to the exhaust manifold and transaxle.

  1. Fully tighten the 2 bolts.

    Torque:
    34 N*m{ 347 kgf*cm , 25 ft.*lbf }


36. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1

  1. A108152
    Install the 3 bolts and exhaust manifold heat insulator No.1.

    Torque:
    8.5 N*m{ 87 kgf*cm , 75 in.*lbf }


37. INSTALL ENGINE WIRE

38. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(Click here)
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