TRANSMISSION CONTROL CABLE INSTALLATION


  1. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

    Note

    Before installing the transmission control cable assembly, check that the park/neutral position switch and the shift lever are in N.


    1. A01CB6K

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

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. A01CGHT

      Connect the transmission control cable to the transmission control cable bracket with a new clip.

    3. A01CB6D

      Put the transmission control cable into the cabin and connect the transmission control cable with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    4. A01CEWX

      Connect the transmission control cable clamp to the body with the 2 nuts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    5. Turn the nut of the transmission control cable 180° counterclockwise. While holding the nut in place, push in the stopper until the stopper clicks twice.

      A01CF4NE01

    6. Install the outer part of the transmission control cable to the shift lever retainer. Check that the spring is positioned at "A" and push in the stopper.

      A01CD6HE01

      Tech Tips

      If the stopper cannot be pushed in, slightly turn the nut clockwise and then push in the stopper again.

    7. A01CE5AE01

      Push the 2 claws together at the top of the transmission control cable lock piece. While holding the 2 claws together, push the 2 lugs on the bottom of the lock piece toward each other and upward to pull out the lock piece.

    8. A01CEMK

      Install the cable end to the shift lever assembly.

      Note


      • Check that the lock piece is pulled up.

      • Install the cable end all the way to the base of the pin.

    9. A01CDVRE01

      Push the lock piece into the adjuster case.

      Note

      Securely push in the lock piece until it locks.

  2. INSTALL NO. 1 DASH PANEL HEAT INSULATOR


    1. A01CDR5

      Install the No. 1 dash panel heat insulator to the body with the 3 nuts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  3. INSTALL EXHAUST MANIFOLD TO HEAD GASKET


    1. A01CE8NE01

      Install a new exhaust manifold to head gasket.

  4. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01CCLIE02

      Using a 12 mm deep socket wrench, install the exhaust manifold sub-assembly RH by tightening the 6 nuts in the order shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. A01CEA1E01

      Connect the air fuel ratio sensor connector (for Bank 1 Sensor 1).

  5. INSTALL MANIFOLD STAY


    1. A01CBF8

      Install the manifold stay with the bolt.

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

  6. INSTALL CENTER EXHAUST PIPE ASSEMBLY


    1. A01CBMY

      Using a vernier caliper, measure the free length of the compression springs.

      Minimum length
      43.0 mm (1.693 in.)

      If the free length is less than the minimum, replace the compression spring.

    2. Fully insert a new gasket to the center exhaust pipe assembly (for Front Side).

    3. A01CFWCE10

      Using a plastic hammer and wooden block, tap in the new gasket until its surface is flush with the center exhaust pipe assembly (for Front Side).

      Note


      • Be sure to install the gasket in the correct direction.

      • Do not reuse the gasket.

      • Do not damage the gasket.

      • Do not push in the gasket by using the exhaust pipe when connecting it.

    4. Install 2 new gaskets to the center exhaust pipe assembly (for Front Side).

    5. A01CDW3

      Install the center exhaust pipe assembly (for Front Side) with the 4 bolts, 2 compression springs and 2 nuts.

      Torque:
      Bolt
      43 N*m  { 440 kgf*cm, 32 ft.*lbf }
      Nut
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

  7. INSTALL BATTERY CARRIER SUPPORT


    1. A01CAMZ

      Install the battery carrier support with the 2 bolts.

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

  8. INSTALL BATTERY CARRIER


    1. A01CCX9

      Insert the No. 2 air cleaner inlet to the battery carrier with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. A01CFOZ

      Install the front bracket with the 4 bolts.

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

    3. Attach the 2 wire harness clamps.

  9. INSTALL AIR CLEANER CASE


    1. A01CFWV

      Install the air cleaner case with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Connect the wire clamp.

    3. Install the air cleaner filter element.

  10. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A01CB66

      Install the air cleaner cap sub-assembly to the air cleaner case with the 2 clamps.

    2. A01CAN5

      Connect the air cleaner hose to the throttle body with the hose clamp.

    3. Connect the ventilation hose.

    4. A01CBVZE01

      Connect the purge line hose.

    5. Connect the 2 wire harness clamps and mass air flow meter connector.

  11. INSTALL BATTERY


    1. Install the battery, battery insulator and battery tray.

    2. A01CDEA

      Install the battery clamp with the bolt and nut.

      Torque:
      Bolt
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }
      Nut
      4.9 N*m  { 50 kgf*cm, 43 in.*lbf }

    3. Connect the positive (+) cable to the battery positive (+) terminal.

      Torque:
      7.6 N*m  { 77 kgf*cm, 67 in.*lbf }

    4. Connect the 2 wire clamps.

  12. INSTALL RADIATOR COVER SUB-ASSEMBLY (for ALPHARD)


    1. Install the radiator cover sub-assembly with the 4 clips.

  13. INSTALL RADIATOR COVER SUB-ASSEMBLY (for VELLFIRE)


    1. Install the radiator cover sub-assembly with the 4 clips.

  14. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. A01CCFB

      Install the outer cowl top panel with the 8 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

    2. Connect the 2 clamps to the outer cowl top panel.

    3. Remove the protective tape.

  15. INSTALL BRAKE MASTER CYLINDER RESERVOIR BRACKET


    1. A01CBAK

      Install the brake master cylinder reservoir with bracket to the outer cowl top panel with the 2 nuts.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  16. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  17. INSTALL OXYGEN SENSOR (for Bank 1 Sensor 2)


    1. A01CFA6

      Install the grommet to the vehicle.

    2. A01CFGU

      Connect the oxygen sensor connector (for Bank 1 Sensor 2).

  18. INSTALL CENTER INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY


    1. Connect the connector.

    2. A01CBOAE01

      Engage the 23 claws to install the center instrument cluster finish panel sub-assembly.

      Note


      • When installing the center instrument cluster finish panel sub-assembly, make sure to press the upper middle part firmly.

      • Make sure that the claws are fully engaged.

    3. Remove the applied protective tape.

    4. Move the shift lever to P.

  19. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY


    1. A01CGCS

      Turn the shift lever knob clockwise to install the shift lever knob sub-assembly.

  20. INSTALL INSTRUMENT CLUSTER FINISH PANEL ASSEMBLY


    1. A01CG2C

      Engage the 15 claws.

      Tech Tips

      Before engaging the 15 claws, make sure that the claws are positioned correctly.

      Note

      Make sure that the claws are fully engaged.

    2. Install the instrument cluster finish panel assembly with the bolt <C>.

  21. INSTALL INSTRUMENT PANEL BOX ASSEMBLY


    1. A01CEC3E01

      With the instrument panel box assembly opened approximately 60° from its closed position, engage the 2 hinges horizontally.

      Note

      Engaging the hinges from the top will deform the hinges. Be sure to install the instrument panel box assembly horizontally.

    2. A01CCWJE01

      Slightly bend stoppers (A) and (B) in the directions indicated by the arrows in the illustration and engage the stoppers to install the instrument panel box assembly.

  22. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY


    1. A01CDTKE01

      With the glove compartment door assembly opened approximately 55° from its closed position, engage the 2 hinges horizontally.

      Note

      Engaging the hinges from the top will deform the hinges. Be sure to install the glove compartment door assembly horizontally.

    2. A01CDIJE01

      Slightly bend stoppers (A) and (B) in the directions indicated by the arrows in the illustration and engage the stoppers to install the glove compartment door assembly.

    3. Engage the claw and connect the glove compartment door stopper.

  23. INSTALL CENTER FLOOR CARPET COVER LH


    1. A01CF5Y

      Engage the 4 claws.

    2. A01CG2A

      Install the center floor carpet cover LH with the clip.

  24. INSTALL CENTER FLOOR CARPET COVER RH (for RHD)


    1. A01CFS0

      Engage the 4 claws.

    2. A01CDKB

      Install the center floor carpet cover RH with the 2 clips.

  25. INSTALL CENTER FLOOR CARPET COVER RH (for LHD)


    1. A01CB02

      Engage the 5 claws.

    2. A01CBO2

      Install the center floor carpet cover RH with the clip.

  26. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (for RHD)


    1. A01CAYP

      Engage the 3 guides and 14 claws.

      Tech Tips

      Make sure that all claws around the entire circumference of the driver side knee airbag assembly are fully engaged.

      Note

      Make sure that the claws are fully engaged.

    2. A01CCKN

      Install the lower instrument panel finish panel with the 3 screws <B>.

    3. A01CC11

      Engage the 3 claws and the fuel lid lock control cable assembly.

    4. A01CC18

      Engage the 3 claws and the hood lock control cable assembly.

  27. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (for LHD)


    1. A01CE7K

      Engage the 3 guides, 13 claws and clip.

      Tech Tips

      Make sure that all claws around the entire circumference of the driver side knee airbag assembly are fully engaged.

      Note

      Make sure that the claws are fully engaged.

    2. A01CCWL

      Install the lower instrument panel finish panel with the 3 screws <B>.

    3. A01CGDM

      Connect the fuel filler opening lid lock sub-assembly to the fuel lid lock open lever sub-assembly.

    4. A01CCXK

      Engage the 3 claws and the fuel lid lock control cable assembly.

    5. A01CF0E

      Engage the 3 claws and the hood lock control cable assembly.

  28. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (for RHD)


    1. A01CE9Q

      Engage the 2 claws and DLC3.

    2. Engage the clamp.

    3. Connect the connector.

    4. A01CFFK

      Engage the 2 claws and 2 guides.

      Note

      Make sure that the claws are fully engaged.

    5. Install the No. 1 instrument panel under cover sub-assembly with the 2 screws <B>.

  29. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (for LHD)


    1. Engage the clamp.

    2. Connect each connector.

    3. A01CCYO

      Engage the 2 claws and guide.

      Note

      Make sure that the claws are fully engaged.

    4. Install the No. 1 instrument panel under cover sub-assembly with the 2 screws <B>.

  30. INSTALL COWL SIDE TRIM BOARD RH (for RHD)


    1. A01CFL6

      Engage the 2 guides, claw and clip to install the cowl side trim board RH.

    2. Install the clip(A).

  31. INSTALL COWL SIDE TRIM BOARD LH (for LHD)


    1. A01CCIK

      Engage the 2 guides, claw and clip to install the cowl side trim board LH.

    2. Install the clip(A).

  32. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  33. INSPECT SHIFT LEVER POSITION


    1. When moving the lever from P to R with the engine switch on (IG) and the brake pedal depressed, make sure that the shift lever moves smoothly and moves correctly into position.

    2. Start the engine and make sure that the vehicle moves forward when moving the lever from N to D and moves rearward when moving the lever to R.

      If the operation cannot be performed as specified, inspect the park/neutral position switch assembly and check the shift lever assembly installation condition.

  34. ADJUST SHIFT LEVER POSITION


    1. Apply the parking brake and move the shift lever to N.

    2. Remove the instrument cluster finish panel assembly and center instrument cluster finish panel sub-assembly Click here.

    3. A01CD5U

      Disconnect the end of the transmission control cable assembly from the shift lever assembly.

    4. A01CE10

      Pull out the stopper of the transmission control cable.

      Note

      Do not remove the stopper. If the stopper is removed, reinstall it to its original position.

    5. A01CDQU

      Rotate the nut counterclockwise approximately 180° and, while holding the nut in that position, disconnect the transmission control cable from the shift lever retainer.

      Note

      Do not over-rotate the nut as it will come off the internal spring and the transmission control cable will not be reusable.

    6. A01CE5AE01

      Push the 2 claws together at the top of the transmission control cable lock piece. While holding the 2 claws together, push the 2 lugs on the bottom of the lock piece toward each other and upward to pull out the lock piece.

    7. Turn the nut of the transmission control cable 180° counterclockwise. While holding the nut in place, push in the stopper until the stopper clicks twice.

      A01CF4NE01

    8. Install the outer part of the transmission control cable to the shift lever retainer. Check that the spring is positioned at "A" and push in the stopper.

      A01CFRKE01

      Tech Tips

      If the stopper cannot be pushed in, slightly turn the nut clockwise and then push in the stopper again.

    9. A01CEMK

      Install the cable end to the shift lever assembly.

      Note


      • Check that the lock piece is pulled up.

      • Install the cable end all the way to the base of the pin.

    10. A01CDVRE01

      Push the lock piece into the adjuster case.

      Note

      Securely press in the lock piece until it locks.

    11. After adjusting the shift lever position, check the operation and function of the shift lever. If there is a problem, adjust the position again.

    12. Install the instrument cluster finish panel assembly and center instrument cluster finish panel sub- assembly Click here.

  35. INSPECT FOR EXHAUST GAS LEAK