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Installation [11/2016 - ]: Procedure

WARNING: This page is about a different car, the 2019 Toyota Highlander, 2018 Toyota Highlander, and 2017 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL TORQUE CONVERTER ASSEMBLY 
    1. Turn the front oil pump drive gear so that either key is at the top and place a matchmark on the transaxle housing to indicate the position of the key.
      GTY689977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Matchmark
      *b Key
    2. Place a matchmark on the torque converter assembly so that the position of its groove is clearly indicated.
      GTY732864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Groove
      *b Matchmark
      MP Grease
    3. Align the matchmark on the torque converter assembly with the one on the transaxle housing and engage the splines of the input shaft with the turbine runner splines.
      NOTE:
      • Install the torque converter assembly to the input shaft while keeping it horizontal.
      • Do not damage the front oil pump oil seal.
      GTY695903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Oil Pump Oil Seal
      *a Matchmark
    4. Rotate the torque converter assembly approximately 180° and engage the splines of the stator shaft with the stator assembly.
      GTY701325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Oil Pump Oil Seal
      *a Matchmark
      NOTE:
      • Do not push the torque converter assembly excessively when rotating it.
      • Install the torque converter assembly to the input shaft while keeping it horizontal.
      • Do not damage the front oil pump oil seal.
    5. Rotate the torque converter assembly approximately 180° again, align the matchmark on the torque converter assembly with the one on the transaxle housing and insert the keys of the front oil pump drive gear into the grooves of the torque converter assembly.
      GTY700310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Oil Pump Oil Seal
      *a Matchmark
      NOTE:
      • Do not push the torque converter assembly excessively when rotating it.
      • Install the torque converter assembly to the input shaft while keeping it horizontal.
      • Do not damage the front oil pump oil seal.
    6. Clean the drive plate and torque converter assembly setting bolt holes.
    7. Using a vernier caliper and straightedge, measure the dimension (A) between the automatic transaxle assembly contact surface of the engine assembly*a and the torque converter assembly contact surface of the drive plate and ring gear sub-assembly*b.
      GTY650647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Engine Assembly Surface
      *b Drive Plate and Ring Gear Sub-assembly Surface
      NOTE:

      Make sure to deduct the thickness of the straightedge.

    8. Using a vernier caliper and straightedge, measure the dimension (B) shown in the illustration and check that the dimension (B) is more than the dimension (A), which was measured in the previous step.
      GTY729182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard

      Dimension (A) + 1 mm (0.0394 in.) or more

      NOTE:
      • Make sure to deduct the thickness of the straightedge.
      • If the automatic transaxle assembly is installed to the engine assembly with the torque converter assembly not sufficiently inserted, the torque converter assembly may be damaged.
      • Do not include the thickness of the set block.
  2. INSTALL BREATHER PLUG HOSE 
    1. Install the breather plug sub-assembly to the breather plug hose.
    2. Install the breather plug hose to the No. 1 breather plug (ATM).
  3. INSTALL TRANSMISSION CASE PLUG ASSEMBLY 
    1. Coat the O-ring of a new transmission case plug assembly with Toyota Genuine ATF WS.
    2. Install the transmission case plug assembly to the automatic transaxle assembly.
  4. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the automatic transaxle case sub-assembly with the bolt.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

  5. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET 
    1. Install the No. 1 transmission control cable bracket to the automatic transaxle case sub-assembly with the 2 bolts.

      Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf) 

  6. INSTALL FRONT ENGINE MOUNTING BRACKET 
    1. Install the front engine mounting bracket to the automatic transaxle assembly with the 4 bolts.

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

  7. INSTALL ENGINE MOUNTING BRACKET LH 
    1. Install the engine mounting bracket LH to the automatic transaxle case sub-assembly with the 3 bolts.

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

  8. INSTALL NO. 1 OIL COOLER TUBE SUB-ASSEMBLY WITHOUT HOSE 

    Refer to PROCEDURE - Step 3

  9. INSTALL TRANSMISSION OIL COOLER 

    Refer to PROCEDURE - Step 2

  10. CONNECT OUTLET NO. 3 OIL COOLER HOSE 

    Refer to PROCEDURE - Step 6

  11. CONNECT INLET NO. 2 OIL COOLER HOSE 

    Refer to PROCEDURE - Step 7

  12. INSTALL TRANSFER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  13. SUPPORT ENGINE ASSEMBLY 
    1. Set an engine lifter.
      GTY718255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that there is clearance between the engine oil pan assembly and engine lifter.

  14. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Apply clutch spline grease to the surface of the crankshaft that contacts the torque converter assembly centerpiece.

      Clutch Spline Grease

      Toyota Genuine Clutch Spline Grease or equivalent

      Maximum Grease Amount

      Approximately 1 g (0.0353 oz)

      GTY690969Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft
      *2 Torque Converter Assembly Centerpiece
      Clutch Spline Grease
    2. Confirm that the 2 knock pins are installed on the engine assembly and are not damaged.
      GTY690647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Knock Pin
    3. While keeping the engine assembly and automatic transaxle assembly horizontal, align the knock pins with the holes in the automatic transaxle assembly and install the automatic transaxle assembly with the 11 bolts shown in the illustration.
      GTY688178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt (A) 

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

      Bolt (B) 

      Torque: 46 N*m (469 kgf*cm, 34 ft.*lbf) 

      Bolt (C) 

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

      Bolt Length

      Bolt Length
      (A) 55 mm (2.17 in.)
      (B) 41 mm (1.61 in.)
      (C) 33 mm (1.30 in.)
      NOTE:
      • Confirm that the knock pins are installed to the automatic transaxle assembly contact surface of the cylinder block sub-assembly before installing the automatic transaxle assembly.
      • Do not forcibly pry on the automatic transaxle assembly.
      • Check that the torque converter assembly rotates.
  15. INSTALL BELT 
    1. Install SST to the vehicle body as shown in the illustration.
      GTY736900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09727-00110 
    2. Using the ratchet buckle, tighten the 2 belts until there is no slack.
      GTY738562Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Ratchet Buckle - -
  16. INSTALL ENGINE MOUNTING INSULATOR LH 
    1. Install the engine mounting insulator LH to the automatic transaxle assembly with the nut.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

  17. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 
    1. Install the front engine mounting insulator assembly to the front engine mounting bracket with the bolt.

      Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

  18. REMOVE ENGINE SUPPORT BAR 
    1. Remove the 2 bolts and SST (support bar) from the vehicle body.
    2. Remove the nut, stud bolt and SST (support bar) from the engine mounting bracket RH.
  19. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH 

    Refer to PROCEDURE - Step 4

  20. INSTALL ENGINE MOUNTING INSULATOR RH 
    1. Install the engine mounting insulator RH to the engine mounting bracket RH with the nut.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

  21. INSTALL TRANSFER STIFFENER PLATE RH 
    1. Temporarily install the transfer stiffener plate RH to the transfer case sub-assembly and rear engine mounting bracket with the 2 bolts (A) and 2 bolts (B).
      GTY737000Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Bolt Length 

      • Bolt (A): 35 mm (1.38 in.)
      • Bolt (B): 75 mm (2.95 in.)
    2. Tighten the 2 bolts (A).

      Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 

    3. Tighten the 2 bolts (B) to install the transfer stiffener plate RH.

      Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf) 

  22. INSTALL FRONT FRAME ASSEMBLY 

    Refer to PROCEDURE - Step 14

  23. REMOVE BELT 
    1. Remove SST from the vehicle body.
      GTY702454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the windshield washer jar assembly to the vehicle body with the bolt and nut.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

  24. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 
    1. Remove any remaining adhesive from the 6 drive plate and torque converter assembly setting bolts.
    2. Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 6 drive plate and torque converter assembly setting bolts.
      GTY447356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Adhesive

      Adhesive

      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

      NOTE:

      Make sure to install the 6 drive plate and torque converter assembly setting bolts immediately after applying adhesive to prevent foreign matter from attaching to them.

    3. Turn the crankshaft to gain access to the installation locations of the 6 drive plate and torque converter assembly setting bolts and install each drive plate and torque converter assembly setting bolt while holding the crankshaft pulley bolt with a wrench.

      Torque: 41 N*m (418 kgf*cm, 30 ft.*lbf) 

      NOTE:

      First install the black colored drive plate and torque converter assembly setting bolt, and then the remaining 5 silver colored drive plate and torque converter assembly setting bolts.

  25. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover to the automatic transaxle case sub-assembly with the 2 bolts.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  26. REMOVE ENGINE SUPPORT BRIDGE 
    1. Remove SST from the vehicle body.
      NOTE:

      Prevent SST from contacting the vehicle body or windshield glass.

  27. REMOVE ENGINE HANGER 
    1. Remove the 2 bolts and No. 2 engine hanger from the cylinder head LH.
    2. Remove the bolt, SST (collar) and No. 1 engine hanger from engine hanger attachment.
    3. Remove the 2 bolts and SST (engine hanger attachment) from cylinder head RH.
  28. CONNECT FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 

    Refer to PROCEDURE - Step 18

  29. CONNECT ENGINE MOUNTING INSULATOR LH 

    Refer to PROCEDURE - Step 19

  30. CONNECT ENGINE MOUNTING INSULATOR RH 

    Refer to PROCEDURE - Step 20

  31. CONNECT REAR ENGINE MOUNTING INSULATOR ASSEMBLY 

    Refer to PROCEDURE - Step 21

  32. CONNECT TRANSMISSION OIL THERMOSTAT 

    Refer to PROCEDURE - Step 22

  33. INSTALL STEERING LINK ASSEMBLY 
    1. Install the steering link assembly to the front frame assembly with the 2 bolts and 2 nuts.

      Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) 

      NOTE:
      • Make sure to tighten the bolts starting from the steering link assembly pinion shaft side.
      • Keep the nut from rotating while turning the bolt because the nut has its own stopper.
  34. INSTALL FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY 
    1. Install the front stabilizer bar with front stabilizer link assembly to the front frame assembly.
  35. INSTALL FRONT NO. 1 STABILIZER BRACKET LH 

    Refer to PROCEDURE - Step 25

  36. INSTALL FRONT NO. 1 STABILIZER BRACKET RH 

    HINT: 

    Use the same procedure as for the LH side.

  37. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING (for LH Side) 

    Refer to PROCEDURE - Step 1

  38. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 2

  39. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  40. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  41. CONNECT TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 12

  42. CONNECT TIE ROD ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  43. INSTALL FRONT SPEED SENSOR 

    Refer to PROCEDURE - Step 10

  44. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 14

  45. INSTALL FRONT AXLE SHAFT NUT 

    Refer to PROCEDURE - Step 11

  46. INSTALL FRONT STABILIZER LINK ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  47. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  48. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY 

    Refer to INSTALLATION [11/2016 - ]

  49. INSTALL EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1) 

    Refer to PROCEDURE - Step 10

  50. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 11

  51. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 7

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

    Refer to PROCEDURE - Step 3

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

    Refer to PROCEDURE - Step 5

  54. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the cylinder head RH with the bolt.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

    2. Engage the hose clamp and 3 wire harness clamps.
    3. Connect the air fuel ratio sensor (for Bank 1) connector.
  55. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 61

  56. INSTALL BREATHER PLUG HOSE 
    1. Engage the 3 hose clamps to install the breather plug hose.
  57. CONNECT ENGINE WIRE 
    1. Engage the clamp to connect the engine wire.
      GTY724036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Transmission Wire Connector
      *b Park/Neutral Position Switch Assembly Connector
      *1 Engine Wire
      *2 Earth Wire
      Bolt
      Nut
    2. Connect the earth wire with the bolt.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

    3. Connect the engine wire to the automatic transaxle case sub-assembly with the 2 bolts and nut.

      Bolt (A) 

      Torque: 25.5 N*m (260 kgf*cm, 19 ft.*lbf) 

      Bolt (B) 

      Torque: 19.1 N*m (195 kgf*cm, 14 ft.*lbf) 

      Nut 

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

    4. Connect the park/neutral position switch connector.
    5. Connect the connector of the transmission wire connector and rotate the lever to engage the claw.

      HINT: 

      Rotate the lever until the claw of the transmission wire connector makes a click sound.

  58. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET 

    Refer to PROCEDURE - Step 10

  59. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 11

  60. CONNECT PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 12

  61. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  62. CONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 13

  63. CONNECT NO. 1 TRANSMISSION OIL COOLER HOSE 

    Refer to PROCEDURE - Step 4

  64. CONNECT OUTLET NO. 1 OIL COOLER HOSE 

    Refer to PROCEDURE - Step 5

  65. INSTALL RADIATOR PIPE ASSEMBLY 
    1. Install the radiator pipe assembly to the automatic transaxle assembly with the bolt.

      Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 

  66. CONNECT NO. 3 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 8

  67. CONNECT NO. 4 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 9

  68. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 42

  69. INSTALL STARTER ASSEMBLY (w/ Stop And Start System) 

    Refer to INSTALLATION [11/2016 - ]

  70. INSTALL STARTER ASSEMBLY (w/o Stop And Start System) 

    Refer to INSTALLATION [11/2016 - ]

  71. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 10

  72. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [12/2013 - ]

  73. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

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

    Refer to INITIALIZATION [11/2016 - ]

  74. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 2

  75. ADD AUTOMATIC TRANSAXLE FLUID 

    Refer to ADJUSTMENT [11/2016 - ]

  76. ADD TRANSFER OIL 

    Refer to PROCEDURE - Step 2

  77. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  78. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  79. INSPECT FOR EXHAUST GAS LEAK 
  80. INSTALL FRONT FENDER APRON SEAL LH 

    Refer to PROCEDURE - Step 97

  81. INSTALL FRONT FENDER APRON SEAL RH 

    Refer to PROCEDURE - Step 98

  82. INSTALL FRONT FENDER LINER LH 

    Refer to PROCEDURE - Step 99

  83. INSTALL FRONT FENDER LINER RH 

    Refer to PROCEDURE - Step 100

  84. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 14

  85. INSTALL NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 102

  86. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 103

  87. INSTALL FRONT WHEELS 

    Refer to PROCEDURE - Step 18

  88. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [11/2016 - ]

  89. CHECK FOR SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [11/2016 - ]

  90. CHECK AUTOMATIC TRANSAXLE SYSTEM 
    NOTE:

    If automatic transaxle parts have been replaced, refer to Parts Replacement Compensation Table to determine if any additional operations are necessary.

    Refer to PRECAUTION [11/2016 - ]

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