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ДВИГАТЕЛЬ В СБОРЕ УСТАНОВКА

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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.

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PROCEDURE


  1. Click here

    INSTALL ENGINE MOUNTING INSULATOR LH

    Tip:

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


    1. A01UFD8N01

      Install the engine mounting insulator LH with the 4 bolts.

      95 N*m 969 kgf*cm 70 ft.*lbf
      Note:

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

    2. Install the bracket to the engine mounting insulator LH with the bolt.

      13 N*m 133 kgf*cm 10 ft.*lbf
  2. Click here

    INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tip:

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


    1. A01UDXON01

      Install the engine mounting insulator sub-assembly RH with the 3 bolts.

      95 N*m 969 kgf*cm 70 ft.*lbf
      Note:

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

    2. Install the bracket to the engine mounting insulator sub-assembly RH with the nut.

      9.8 N*m 100 kgf*cm 87 in.*lbf

    3. Connect the 4 clamps to the bracket.

  3. Click here

    INSTALL ENGINE HANGER

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  4. Click here

    REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  5. Click here

    INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  6. Click here

    INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  7. Click here

    INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

    Click here

  8. Click here

    CONNECT ENGINE WIRE

    Click here

  9. Click here

    TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR

    Tip:

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


    1. A01UCV9

      Temporarily install the rear engine mounting insulator to the rear engine mounting bracket with the bolt.

  10. Click here

    INSTALL FRONT ENGINE MOUNTING BRACKET

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  11. Click here

    TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. A01UEX9

      Temporarily install the front engine mounting insulator to the front engine mounting bracket with the bolt and nut.

  12. Click here

    INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Tip:

    Perform "Inspection After Repair" after replacing the engine assembly.

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    1. Set the engine assembly with transaxle on an engine lifter.

      Note:

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

      • 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.

      • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

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

    3. 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.

      Note:

      • 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.

    4. Install the engine mounting insulator LH to the engine mounting bracket LH with the bolt and nut.

      56 N*m 571 kgf*cm 41 ft.*lbf
      Note:

      While holding the bolt in place, tighten the nut.

    5. A01UDFLN01

      Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the bolt and 2 nuts.

      Bolt and Nut (A)
      95 N*m 969 kgf*cm 70 ft.*lbf
      Nut (B)
      52 N*m 530 kgf*cm 38 ft.*lbf
    6. A01UEK6

      Install the front crossmember sub-assembly with the 4 bolts.

      96 N*m 979 kgf*cm 71 ft.*lbf
    7. A01UD2ZN01

      Install the front engine mounting insulator to the front crossmember sub-assembly with the 2 bolts.

      95 N*m 969 kgf*cm 70 ft.*lbf
      Note:

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

  13. Click here

    INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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  14. Click here

    INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY LH

    Click here

  15. Click here

    INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY RH

    Tip:

    Use the same procedure as for the LH side.

  16. Click here

    INSTALL REAR ENGINE MOUNTING INSULATOR

    Tip:

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


    1. Tighten the bolt of the rear engine mounting insulator.

      95 N*m 969 kgf*cm 70 ft.*lbf
  17. Click here

    INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Tighten the bolt and nut of the front engine mounting insulator.

      95 N*m 969 kgf*cm 70 ft.*lbf
      Note:

      While holding the nut in place, tighten the bolt.

  18. Click here

    INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

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  19. Click here

    INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover to the stiffening crankcase assembly.

  20. Click here

    INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

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  21. Click here

    INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Tip:

    Use the same procedure as for the LH side.

  22. Click here

    INSTALL FRONT DRIVE SHAFT ASSEMBLY

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  23. Click here

    INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

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  24. Click here

    CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

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  25. Click here

    CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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  26. Click here

    INSTALL COLUMN HOLE COVER SILENCER SHEET

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  27. Click here

    CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Connect the transmission control cable assembly with the transmission control cable support to the continuously variable transaxle assembly with the bolt.

      5.0 N*m 51 kgf*cm 44 in.*lbf

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

    3. Connect the transmission control cable assembly to the control shaft lever with the nut.

      12 N*m 122 kgf*cm 9 ft.*lbf
  28. Click here

    CONNECT BREATHER PLUG HOSE


    1. Connect the breather plug hose to the clamp.

  29. Click here

    INSTALL AIR CLEANER HOSE ASSEMBLY

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  30. Click here

    CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the No. 1 fuel vapor feed hose to the No. 1 vacuum switching valve assembly and slide the clip to secure it.

  31. Click here

    INSTALL UNION TO CHECK VALVE HOSE

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  32. Click here

    CONNECT FUEL TUBE SUB-ASSEMBLY

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  33. Click here

    INSTALL STARTER ASSEMBLY

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  34. Click here

    CONNECT WIRE HARNESS


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

      8.4 N*m 86 kgf*cm 74 in.*lbf

    2. Engage the clamp to the continuously variable transaxle.

    3. Engage the clamp to connect the No. 2 engine wire to the bracket.

    4. A01UDI5N01

      Connect the engine wire with the 2 bolts.

      Bolt (A)
      8.4 N*m 86 kgf*cm 74 in.*lbf
      Bolt (B)
      13 N*m 133 kgf*cm 10 ft.*lbf

    5. Engage the 4 clamps.

    6. Engage the 4 claws to install the engine wire to the engine room relay block assembly.

    7. Install the nut to the engine room relay block assembly.

      10.5 N*m 107 kgf*cm 8 ft.*lbf

    8. Connect the connector (C) to the engine room relay block assembly.

    9. Push down the lock lever to connect (D) the connector to the engine room relay block assembly.

      Note:

      Be sure to securely connect the connector.

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

  35. Click here

    CONNECT HEATER HOSE


    1. Connect the heater water inlet hose to the cylinder head sub-assembly and slide the clip to secure it.

    2. Connect the water hose sub-assembly to the No. 1 water by-pass pipe and slide the clip to secure it.

    3. Engage the clamp and connect the water hose sub-assembly.

    4. Connect the No. 2 water by-pass hose to the oil cooler and slide the 2 clips to secure it.

    5. Engage the clamp and connect the No. 2 water by-pass hose to the No. 1 radiator hose.

  36. Click here

    CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

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  37. Click here

    CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

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  38. Click here

    CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the cylinder head sub-assembly and slide the clip to secure it.

    2. Connect the air fuel ratio sensor wire to the No. 1 radiator hose with the radiator hose clamp.

  39. Click here

    CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.

  40. Click here

    INSTALL GENERATOR ASSEMBLY

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  41. Click here

    INSTALL V-RIBBED BELT

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  42. Click here

    INSTALL BATTERY CARRIER SUPPORT

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  43. Click here

    INSTALL BATTERY CARRIER

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  44. Click here

    INSTALL ECM

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  45. Click here

    INSTALL RADIATOR RESERVE TANK BRACKET


    1. Install the radiator reserve tank bracket with the 2 bolts.

      12 N*m 122 kgf*cm 9 ft.*lbf
  46. Click here

    INSTALL RADIATOR RESERVE TANK ASSEMBLY


    1. Install the radiator reserve tank assembly to the radiator reserve tank bracket with the bolt.

      12 N*m 122 kgf*cm 9 ft.*lbf
      Note:

      Insert the protrusion of the radiator reserve tank assembly into the grommet of the radiator reserve tank bracket.

    2. Connect the water by-pass hose and No. 2 water by-pass hose to the radiator reserve tank assembly and slide the 2 clips to secure them.

  47. Click here

    INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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  48. Click here

    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


    1. Connect the cable to the negative (-) battery terminal with the nut.

      5.4 N*m 55 kgf*cm 48 in.*lbf
      Note:

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  49. Click here

    ADD ENGINE OIL

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  50. Click here

    ADD ENGINE COOLANT

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  51. Click here

    ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID

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  52. Click here

    CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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  53. Click here

    WARM UP ENGINE

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  54. Click here

    INSPECT SHIFT LEVER POSITION

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  55. Click here

    ADJUST SHIFT LEVER POSITION

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  56. Click here

    INSPECT FOR ENGINE OIL LEAK

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  57. Click here

    INSPECT FOR COOLANT LEAK

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  58. Click here

    INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID

  59. Click here

    INSPECT REFRIGERANT LEAK

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  60. Click here

    INSPECT FOR FUEL LEAK

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  61. Click here

    INSPECT FOR EXHAUST GAS LEAK

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  62. Click here

    CHECK ENGINE OIL LEVEL

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  63. Click here

    INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

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  64. Click here

    INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the 5 clips.

  65. Click here

    INSTALL REAR ENGINE UNDER COVER RH


    1. Install the rear engine under cover RH with the 5 clips.

  66. Click here

    INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 5 clips.

  67. Click here

    INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 engine under cover with the 2 bolts and 5 clips.

  68. Click here

    INSTALL FRONT LOWER BUMPER ABSORBER

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  69. Click here

    INSTALL FRONT BUMPER COVER

    for ALPHARD:Click here

    for VELLFIRE:Click here

  70. Click here

    INSTALL FRONT WHEELS

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  71. Click here

    ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  72. Click here

    INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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  73. Click here

    PERFORM INITIALIZATION

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  74. Click here

    INSPECT IGNITION TIMING

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  75. Click here

    INSPECT ENGINE IDLE SPEED

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  76. Click here

    INSPECT CO/HC

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  77. Click here

    CHECK SPEED SENSOR SIGNAL

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