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. B006NKWN01

      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 wire harness bracket to the engine mounting insulator LH with the bolt.

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

    3. Connect the clamp to the wire harness bracket.

  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. B006RFCN01

      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 cooler 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 cooler bracket.

  3. INSTALL ENGINE HANGERS

    Click here

  4. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

    Click here

  7. INSTALL STARTER ASSEMBLY

    Click here

  8. INSTALL TRANSMISSION BREATHER SKIRT

    Click here

  9. INSTALL DRIVE SHAFT BEARING BRACKET


    1. Install the drive shaft bearing bracket with the 3 bolts.

      Torque:
      63.7 N*m  { 650 kgf*cm, 47 ft.*lbf }

  10. INSTALL COMPRESSOR AND MAGNETIC CLUTCH

    Click here

  11. INSTALL GENERATOR ASSEMBLY

    Click here

  12. INSTALL V-RIBBED BELT

    Click here

  13. INSTALL MANIFOLD STAY

    Click here

  14. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  15. TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B006LO2

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

  16. INSTALL FRONT ENGINE MOUNTING BRACKET

    Click here

  17. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. B006QTB

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

  18. 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 4 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. B006LYJN01

      Install the engine mounting insulator sub-assembly RH to the front No. 1 engine mounting bracket LH with the 2 bolts 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. B006LF6

      Install the No. 2 engine mounting stay RH with the bolt and 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    7. B006NHA

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

      Torque:
      96 N*m  { 979 kgf*cm, 71 ft.*lbf }
    8. B006KZGN01

      Install the front engine mounting insulator to the front crossmember sub-assembly 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).

  19. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  20. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY LH

    Click here

  21. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  22. 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 }

  23. INSTALL FRONT ENGINE MOUNTING INSULATOR


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

      Torque:
      145 N*m  { 1479 kgf*cm, 107 ft.*lbf }

      Note

      While holding the nut in place, tighten the bolt.

  24. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  25. INSTALL FLYWHEEL HOUSING UNDER COVER


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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  26. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  27. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Tech Tips

    Use the same procedure as for the LH side.

  28. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

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

    Click here

  30. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  31. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  32. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  33. CONNECT ENGINE WIRE


    1. Connect the No. 3 engine wire to the automatic transaxle assembly with the bolt and clamp.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Connect terminal 30 with the nut.

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

    3. Close the terminal cap.

    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.

  34. CONNECT FUEL MAIN TUBE


    1. Connect the fuel main tube to the fuel pipe.

      Click here

  35. CONNECT UNION TO CONNECTOR TUBE HOSE


    1. Connect the union to connector tube hose to the intake air surge tank assembly and slide the clip to secure it.

  36. CONNECT NO. 1 FUEL VAPOR FEED HOSE


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

  37. CONNECT OUTLET HEATER WATER HOSE


    1. Connect the outlet heater water hose to the water outlet and slide the clip to secure it.

  38. CONNECT INLET HEATER WATER HOSE


    1. Connect the inlet heater water hose to the water inlet and slide the clip to secure it.

  39. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the water outlet 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.

  40. INSTALL ECM

    Click here

  41. CONNECT NO. 2 RADIATOR HOSE


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

  42. 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 }

  43. 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 No. 1 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.

  44. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE


    1. Remove the attached vinyl tape from the hose.

    2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring onto the No. 1 cooler refrigerant discharge hose.

    4. Connect the No. 1 cooler refrigerant discharge hose with the nut.

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

  45. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE


    1. Remove the attached vinyl tape from the hose.

    2. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.

      Compressor oil
      ND-OIL 8 or equivalent

    3. Install the O-ring onto the No. 1 cooler refrigerant suction hose.

    4. Connect the No. 1 cooler refrigerant suction hose with the nut.

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

    5. Connect the clamp.

  46. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  47. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Upper Side)


    1. Install the No. 1 exhaust pipe support bracket with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  48. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  49. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side)

    Click here

  50. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY

    Click here

  51. CONNECT OIL COOLER HOSE


    1. Connect the outlet oil cooler hose and inlet oil cooler hose and slide the 2 clips to secure them.

  52. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


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

      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

  53. ADD ENGINE OIL

    Click here

  54. ADD ENGINE COOLANT

    Click here

  55. ADD AUTOMATIC TRANSAXLE FLUID

    Click here

  56. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  57. WARM UP ENGINE

    Click here

  58. INSPECT SHIFT LEVER POSITION

    Click here

  59. ADJUST SHIFT LEVER POSITION

    Click here

  60. INSPECT FOR ENGINE OIL LEAK

    Click here

  61. INSPECT FOR COOLANT LEAK

    Click here

  62. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK

    Click here

  63. INSPECT FOR REFRIGERANT LEAK

    Click here

  64. INSPECT FOR FUEL LEAK

    Click here

  65. INSPECT FOR EXHAUST GAS LEAK

    Click here

  66. INSPECT ENGINE OIL LEVEL

    Click here

  67. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

    Click here

  68. INSTALL REAR ENGINE UNDER COVER LH


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

  69. INSTALL REAR ENGINE UNDER COVER RH


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

  70. INSTALL NO. 2 ENGINE UNDER COVER


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

  71. INSTALL NO. 1 ENGINE UNDER COVER


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

  72. INSTALL FRONT LOWER BUMPER ABSORBER

    Click here

  73. INSTALL FRONT BUMPER COVER

    for ALPHARD: Click here

    for VELLFIRE: Click here

  74. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. B006RGLN01

      Attach the 3 clips in the order shown in the illustration to install the V-bank cover sub-assembly.

      Note


      • Securely attach the clips.

      • If the clips are forcibly attached or struck with an object, they may be damaged.

  75. INSTALL FRONT WHEELS

    Click here

  76. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

    Click here

  77. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  78. PERFORM INITIALIZATION

    Click here

  79. INSPECT IGNITION TIMING

    Click here

  80. INSPECT ENGINE IDLE SPEED

    Click here

  81. INSPECT CO/HC

    Click here

  82. CHECK FOR SPEED SENSOR SIGNAL

    Click here