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Home >> Toyota >> 2009 >> Highlander Limited, FWD >> Repair and Diagnosis >> Electrical >> Charging Systems >> Charging System (2GR-FE) >> Removal >> Installation

Charging System (2GR-FE): Removal: Installation

  1. INSTALL GENERATOR ASSEMBLY 
    1. Install the wire harness clamp stay with the bolt.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      Fig 1: Locating Wire Harness Clamp Stay Bolt
      G05415440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the generator bracket with the wire harness clamp.
      Fig 2: Identifying Generator Bracket And Wire Harness Clamp
      G05415439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install generator assembly with the 2 bolts.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      Fig 3: Locating Generator Assembly Bolts
      G05415438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Temporally install the 2 bolts.
      Fig 4: Locating Generator Bracket Bolts
      G05415437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Fully tighten the 2 bolts.

      Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) 

      Fig 5: Locating Generator Bracket Bolts
      G05415437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the generator connector to the generator assembly.
    7. Install the generator wire with the nut.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

    8. Install the terminal cap.
    9. Connect the 3 wire harness clamps.
    10. Connect the magnetic clutch connector to the compressor and magnetic clutch.
    Fig 6: Identifying Wire Harness Clamps
    G05415436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL V-RIBBED BELT  (See INSTALLATION )
  3. INSTALL NO. 2 OIL LEVEL DIPSTICK GUIDE 
    1. Install a new O-ring to the No. 2 oil level dipstick guide.
    2. Apply a light coat of engine oil to the O-ring.
    3. Push in the No. 2 oil level dipstick guide end into the No. 1 oil level dipstick guide.
    4. Install the No. 2 oil level dipstick guide with the bolt.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

    Fig 7: Locating No. 2 Oil Level Dipstick Guide Bolt
    G05415435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSTALL RADIATOR ASSEMBLY AND FAN ASSEMBLY WITH MOTOR  (See INSTALLATION )
  5. INSTALL COOLER CONDENSER ASSEMBLY  (See INSTALLATION )
  6. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY  (See INSTALLATION )
  7. INSTALL HOOD LOCK ASSEMBLY (w/o Engine Hood Courtesy Switch)  (See INSTALLATION )
  8. INSTALL HOOD LOCK ASSEMBLY (w/ Engine Hood Courtesy Switch)  (See INSTALLATION )
  9. INSTALL RADIATOR GRILLE  (See INSTALLATION )
  10. CONNECT COOLING FAN ECU CONNECTOR  (See INSTALLATION )
  11. CONNECT OIL COOLER HOSE  (See INSTALLATION )
  12. CONNECT NO. 2 RADIATOR HOSE  (See INSTALLATION )
  13. CONNECT NO. 1 RADIATOR HOSE  (See INSTALLATION )
  14. INSTALL NO. 1 AIR CLEANER INLET  (See INSTALLATION )
  15. INSTALL NO. 2 AIR CLEANER INLET  (See INSTALLATION )
  16. INSTALL BATTERY  (See INSTALLATION )
  17. INSTALL COOL AIR INTAKE DUCT SEAL  (See INSTALLATION )
  18. INSTALL FRONT FENDER APRON SEAL RH  (See INSTALLATION )
  19. INSTALL FRONT FENDER LINER RH  (See INSTALLATION )
  20. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH 

    HINT:

    Use the same procedures for the RH side and LH side (See INSTALLATION ).

  21. ADD ENGINE COOLANT  (See REPLACEMENT )
  22. INSPECT FOR COOLANT LEAK  (See COOLING SYSTEM )
  23. INSPECT AUTOMATIC TRANSAXLE FLUID  (See INSTALLATION )
  24. INSPECT FOR OIL LEAK 
  25. INSTALL NO. 1 ENGINE UNDER COVER  (See INSTALLATION )
  26. INSTALL ENGINE UNDER COVER ASSEMBLY  (See INSTALLATION )
  27. INSTALL FRONT WHEEL RH 

    Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 

  28. INSTALL V-BANK COVER SUB-ASSEMBLY  (See INSTALLATION )
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