ENGINE ASSEMBLY INSTALLATION

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.

PROCEDURE


  1. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B006P3PN01

      Install the engine mounting insulator LH with the 4 bolts.

      Torque:
      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.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  2. INSTALL 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. B006MZVN01

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

      Torque:
      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.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    3. Connect the 4 clamps to the bracket.

  3. INSTALL ENGINE HANGER

    Click here

  4. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  5. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  6. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  7. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

    Click here

  8. CONNECT ENGINE WIRE

    Click here

  9. TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B006PQD

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

  10. INSTALL FRONT ENGINE MOUNTING BRACKET

    Click here

  11. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. B006KXN

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

  12. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Tech Tips

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

    Click here


    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.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

      Note

      While holding the bolt in place, tighten the nut.

    5. B006OYSN01

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

      Torque:
      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. B006PDF

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

      Torque:
      96 N*m  { 979 kgf*cm, 71 ft.*lbf }
    7. B006PNEN01

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

      Torque:
      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. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  14. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY LH

    Click here

  15. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  16. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


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

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

  17. INSTALL FRONT ENGINE MOUNTING INSULATOR


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

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

      Note

      While holding the nut in place, tighten the bolt.

  18. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  19. INSTALL FLYWHEEL HOUSING UNDER COVER


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

  20. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  21. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Tech Tips

    Use the same procedure as for the LH side.

  22. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  23. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

    Click here

  24. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  25. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  26. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  27. 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.

      Torque:
      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.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  28. CONNECT BREATHER PLUG HOSE


    1. Connect the breather plug hose to the clamp.

  29. INSTALL AIR CLEANER HOSE ASSEMBLY

    Click here

  30. 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. INSTALL UNION TO CHECK VALVE HOSE

    Click here

  32. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  33. INSTALL STARTER ASSEMBLY

    Click here

  34. CONNECT WIRE HARNESS


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

      Torque:
      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. B006MYCN01

      Connect the engine wire with the 2 bolts.

      Torque:
      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.

      Torque:
      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. 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. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  37. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

    Click here

  38. 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. CONNECT NO. 2 RADIATOR HOSE


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

  40. INSTALL GENERATOR ASSEMBLY

    Click here

  41. INSTALL V-RIBBED BELT

    Click here

  42. INSTALL BATTERY CARRIER SUPPORT

    Click here

  43. INSTALL BATTERY CARRIER

    Click here

  44. INSTALL ECM

    Click here

  45. INSTALL RADIATOR RESERVE TANK BRACKET


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

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  46. INSTALL RADIATOR RESERVE TANK ASSEMBLY


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

      Torque:
      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. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    Click here

  48. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


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

      Torque:
      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.

      Click here

  49. ADD ENGINE OIL

    Click here

  50. ADD ENGINE COOLANT

    Click here

  51. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID

    Click here

  52. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  53. WARM UP ENGINE

    Click here

  54. INSPECT SHIFT LEVER POSITION

    Click here

  55. ADJUST SHIFT LEVER POSITION

    Click here

  56. INSPECT FOR ENGINE OIL LEAK

    Click here

  57. INSPECT FOR COOLANT LEAK

    Click here

  58. INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID

  59. INSPECT REFRIGERANT LEAK

    Click here

  60. INSPECT FOR FUEL LEAK

    Click here

  61. INSPECT FOR EXHAUST GAS LEAK

    Click here

  62. CHECK ENGINE OIL LEVEL

    Click here

  63. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

    Click here

  64. INSTALL REAR ENGINE UNDER COVER LH


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

  65. INSTALL REAR ENGINE UNDER COVER RH


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

  66. INSTALL NO. 2 ENGINE UNDER COVER


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

  67. INSTALL NO. 1 ENGINE UNDER COVER


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

  68. INSTALL FRONT LOWER BUMPER ABSORBER

    Click here

  69. INSTALL FRONT BUMPER COVER

    for ALPHARD: Click here

    for VELLFIRE: Click here

  70. INSTALL FRONT WHEELS

    Click here

  71. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  72. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  73. PERFORM INITIALIZATION

    Click here

  74. INSPECT IGNITION TIMING

    Click here

  75. INSPECT ENGINE IDLE SPEED

    Click here

  76. INSPECT CO/HC

    Click here

  77. CHECK SPEED SENSOR SIGNAL

    Click here