ENGINE ASSEMBLY REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the engine assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link
Battery terminal is disconnected/reconnected Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes) Stop and start system

Click here

Memorize steering angle neutral point Panoramic view monitor system

Click here

Initialize back door lock Power door lock control system

Click here

Initialize servo motor Air conditioning system

Click here

Reset slide door close position Power slide door system

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Reset back door close position Power back door system

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Replacement of ECM Perform Vehicle Identification Number (VIN) or frame number registration DTC is stored

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ECU Communication ID Registration (Immobiliser system) Engine start function See Service Bulletin for the registration method.
Perform code registration (Immobiliser system)

  • Wireless door lock control system

  • Smart entry and start system

  • Engine start function

  • Steering lock system

 See Service Bulletin for the registration method.

Perform the following procedures in the order shown:


  1. Reset Memory

  2. Deceleration Sensor 0 Point Calibration

  3. CVT Oil Pressure Calibration

  • DTCs are stored

  • Neutral control is prohibited

  • Deterioration of fuel efficiency

Click here

Replacement of continuously variable transaxle assembly

Perform the following procedures in the order shown:


  1. Reset Memory

  2. Deceleration Sensor 0 Point Calibration

  3. CVT Oil pressure Calibration

  • DTCs are stored

  • Neutral control is prohibited

  • Deterioration of fuel efficiency

Click here

Replacement of CVT fluid ATF thermal degradation estimate reset The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly

  • Replacement of engine assembly

  • Gas leak from exhaust system is repaired

 Inspection After Repair

  • Poor idle, etc.

  • Engine start function, etc.

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Replacement of starter assembly

Note

When the starter assembly is replaced, "ST NO. 1 relay" and "ST NO. 2 relay" must be also replaced.

 Clear Number of Starter Operations Stop and start system

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  • Replacement of continuously variable transaxle assembly

  • Replacement of CVT fluid

 Bleed the oil pump assembly with motor (continuously variable transaxle assembly)
Replacement of battery Switch battery type
Front wheel alignment adjustment

  1. Clear zero point calibration data and store system information.

  2. Perform yaw rate and acceleration sensor zero point calibration and store system information.

  • VSC disabled or malfunctions

  • DTCs are stored

  • Slip indicator light illuminates

  • ABS warning light illuminates

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Work that changes the vehicle height such as replacement or removal/installation of the rear height control sensor sub-assembly LH or replacement of suspension components Initialize headlight light control ECU sub-assembly LH Headlight leveling function

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Removal/installtaion of the radiator grille Television camera view adjustment Panoramic view monitor system

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CAUTION:


  • B006LBSC01
    *a An Object Exceeding Weight Limit of Engine Lifter

    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.

  • B006QE7

    To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

PROCEDURE


  1. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Click here

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

    Click here

  3. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  5. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  6. SECURE STEERING WHEEL

    Click here

  7. REMOVE FRONT WHEELS

    Click here

  8. REMOVE FRONT BUMPER COVER

    for ALPHARD: Click here

    for VELLFIRE: Click here

  9. REMOVE FRONT LOWER BUMPER ABSORBER

    Click here

  10. REMOVE NO. 1 ENGINE UNDER COVER


    1. Remove the 2 bolts, 5 clips and No. 1 engine under cover.

  11. REMOVE NO. 2 ENGINE UNDER COVER


    1. Remove the 5 clips and No. 2 engine under cover.

  12. REMOVE REAR ENGINE UNDER COVER LH


    1. Remove the 5 clips and rear engine under cover LH.

  13. REMOVE REAR ENGINE UNDER COVER RH


    1. Remove the 5 clips and rear engine under cover RH.

  14. DRAIN ENGINE COOLANT

    Click here

  15. DRAIN ENGINE OIL

    Click here

  16. DRAIN CONTINUOUSLY VARIABLE TRANSAXLE FLUID

    Click here

  17. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  18. REMOVE RADIATOR RESERVE TANK ASSEMBLY


    1. B006LECC01
      *1 Water By-pass Hose
      *2 No. 2 Water By-pass Hose
      *a Grommet
      *b Protrusion

      Slide the 2 clips and disconnect the water by-pass hose and No. 2 water by-pass hose from the radiator reserve tank assembly.

    2. Remove the bolt and radiator reserve tank assembly from the radiator reserve tank bracket.

  19. REMOVE RADIATOR RESERVE TANK BRACKET


    1. B006P8Q

      Remove the 2 bolts and radiator reserve tank bracket.

  20. REMOVE ECM

    Click here

  21. REMOVE BATTERY CARRIER

    Click here

  22. REMOVE BATTERY CARRIER SUPPORT

    Click here

  23. REMOVE V-RIBBED BELT

    Click here

  24. REMOVE GENERATOR ASSEMBLY

    Click here

  25. DISCONNECT NO. 2 RADIATOR HOSE


    1. B006P71

      Slide the clip and disconnect the No. 2 radiator hose from the water inlet.

  26. DISCONNECT NO. 1 RADIATOR HOSE


    1. B006MZW

      Remove the radiator hose clamp to disconnect the air fuel ratio sensor wire from the No. 1 radiator hose.

    2. Slide the clip and disconnect the No. 1 radiator hose from the cylinder head sub-assembly.

  27. DISCONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

    Click here

  28. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  29. DISCONNECT HEATER HOSE


    1. B006LUPC01
      *1 No. 2 Water By-pass Hose
      *2 Water Hose Sub-assembly
      *3 Heater Water Inlet Hose

      Disengage the clamp and disconnect the No. 2 water by-pass hose from the No. 1 radiator hose.

    2. Slide the 2 clips and disconnect the No. 2 water by-pass hose from the oil cooler.

    3. Disengage the clamp and disconnect the water hose sub-assembly.

    4. Slide the clip and disconnect the water hose sub-assembly from the No. 1 water by-pass pipe.

    5. Slide the clip and disconnect the heater water inlet hose from the cylinder head sub-assembly.

  30. DISCONNECT WIRE HARNESS

    Tech Tips

    After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way.


    1. B006NUM

      Remove the No. 1 relay block cover from the engine room relay block assembly.

    2. B006QRNC02
      *a Push

      Pull up the lock lever and disconnect the connector (A).

    3. Disconnect the connector (B) from the engine room relay block assembly.

    4. Remove the nut from the engine room relay block assembly.

    5. Using a screwdriver, disengage the 4 claws and separate the engine wire from the engine room relay block assembly.

    6. Disengage the 4 clamps.

    7. Remove the 2 bolts to disconnect the engine wire.

    8. B006NCH

      Disengage the clamp to disconnect the No. 2 engine wire from the bracket.

    9. B006NSN

      Disengage the clamp from the continuously variable transaxle assembly.

    10. Remove the bolt and disconnect the No. 3 engine wire from the continuously variable transaxle assembly.

  31. REMOVE STARTER ASSEMBLY

    Click here

  32. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  33. SEPARATE UNION TO CHECK VALVE HOSE

    Click here

  34. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. B006PV8

      Slide the clip and disconnect the No. 1 fuel vapor feed hose from the No. 1 vacuum switching valve assembly.

  35. REMOVE AIR CLEANER HOSE ASSEMBLY

    Click here

  36. DISCONNECT BREATHER PLUG HOSE


    1. B006LIN

      Disconnect the breather plug hose from the clamp.

  37. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. B006N3OC01
      *1 Transmission Control Cable Assembly
      *2 No. 1 Transmission Control Cable Bracket

      Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.

    2. Remove the clip and disconnect the transmission control cable assembly from the No. 1 transmission control cable bracket.

    3. B006NM3

      Remove the bolt and disconnect the transmission control cable assembly with the transmission control cable support from the continuously variable transaxle assembly.

  38. REMOVE COLUMN HOLE COVER SILENCER SHEET

    Click here

  39. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  40. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  41. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

    Click here

  42. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  43. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  44. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Tech Tips

    Use the same procedure as for the LH side.

  45. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. B006KPG

      Remove the flywheel housing under cover from the stiffening crankcase assembly.

  46. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  47. REMOVE FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY LH

    Click here

  48. REMOVE FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  49. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  50. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    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 position the height adjustment attachments or plate lift attachments under the front cross member sub-assembly.

      • 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 engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to 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. B006NGW

      Remove the 6 bolts and front crossmember sub-assembly.

    3. B006OYS

      Remove the bolt and 2 nuts and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.

    4. B006M4F

      Remove the bolt and nut and separate the engine mounting insulator LH from the engine mounting bracket LH.

    5. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.

      Note


      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

      • While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.

  51. INSTALL ENGINE HANGER


    1. B006QSBC06
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts as shown in the illustration.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Tech Tips

      No. 1 Engine Hanger 12281-0V010
      No. 2 Engine Hanger 12282-0V030
      Bolt (No. 1 Engine Hanger)

      91552-81040

      90105-C0170
      Bolt (No. 2 Engine Hanger)

      91552-81025

      90105-C0169

    2. Using an engine sling device and engine lift, secure the engine assembly with transaxle.

      Note


      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.

      • 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.

  52. REMOVE FRONT ENGINE MOUNTING INSULATOR


    1. B006KXN

      Remove the bolt, nut and front engine mounting insulator from the front engine mounting bracket.

      Note

      While holding the nut in place, loosen the bolt.

  53. REMOVE FRONT ENGINE MOUNTING BRACKET

    Click here

  54. REMOVE REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B006PQD

      Remove the bolt and rear engine mounting insulator from the rear engine mounting bracket.

  55. DISCONNECT ENGINE WIRE

    Click here

  56. REMOVE CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

    Click here

  57. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  58. REMOVE ENGINE WIRE


    1. Remove the engine wire from the engine assembly.

  59. INSTALL ENGINE ASSEMBLY TO ENGINE STAND


    1. Install the engine assembly to an engine stand.

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

  60. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

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


    1. B006LS6

      Disconnect the 4 clamps from the bracket.

    2. Remove the nut and bracket from the engine mounting insulator sub-assembly RH.

    3. B006MZV

      Remove the 3 bolts and engine mounting insulator sub-assembly RH.

  61. REMOVE ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B006Q3G

      Remove the bolt and bracket from the engine mounting insulator LH.

    2. B006P3P

      Remove the 4 bolts and engine mounting insulator LH.