LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2017 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 13 (Engine Mechanical (2GR-FE) (Service Information) (Except Hybrid) (1 Of 2)) >> Engine Assembly & Engine Under Cover >> Installation [12/2013 - 11/2016] >> Procedure

Installation [12/2013 - 11/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Highlander, 2015 Toyota Highlander, and 2014 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL ENGINE HANGERS 

    See step  62

  2. REMOVE ENGINE FROM ENGINE STAND 
    1. Using an engine sling device and engine lift, secure the engine assembly.
      NOTE:
      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.
      • 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.
    2. Remove the engine assembly from the engine stand.
  3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  2

  4. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) 

    Refer to PROCEDURE - Step 6 , or refer to PROCEDURE - Step 6

  5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 7 , or refer to PROCEDURE - Step 7

  6. INSTALL TRANSFER STIFFENER PLATE RH (for AWD) 

    Refer to PROCEDURE - Step 8 , or refer to PROCEDURE - Step 8

  7. INSTALL RADIATOR PIPE CLAMP (for 2WD) 

    Refer to PROCEDURE - Step 7 , or refer to PROCEDURE - Step 7

  8. INSTALL RADIATOR PIPE CLAMP (for AWD) 

    Refer to PROCEDURE - Step 9 , or refer to PROCEDURE - Step 9

  9. INSTALL ENGINE WIRE 
    1. Install the engine wire to the engine assembly with transaxle.
  10. INSTALL MANIFOLD STAY 

    Refer to PROCEDURE - Step 12

  11. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 

    HINT: 

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

    1. Temporarily install the front engine mounting insulator assembly with the 3 nuts.
  12. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH 

    HINT: 

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

    1. Temporarily install the engine mounting insulator LH with the 3 nuts.
  13. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH 

    HINT: 

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

    1. Temporarily install the engine mounting insulator RH with the 3 nuts.
  14. TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY 

    HINT: 

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

    1. Temporarily install the rear engine mounting insulator with the 2 nuts.
  15. INSTALL FRONT FRAME ASSEMBLY 
    1. Install the engine mounting insulator RH with the nut.

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

    2. Install the engine mounting insulator LH with the nut.

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

    3. Install the front engine mounting insulator assembly with the bolt.

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

    4. Install the rear engine mounting insulator assembly with the 2 bolts.

      Torque: 75 N*m (765 kgf*cm, 55 ft.*lbf) 

    5. Connect the 2 wire clamps.
    6. Fully tighten the 11 temporarily installed nuts of the engine mounting insulators.

      HINT: 

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

      GTY450828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Engine Mounting Insulator Assembly *2 Engine Mounting Insulator RH
      *3 Engine Mounting Insulator LH *4 Rear Engine Mounting Insulator

      Nut (A) 

      Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf) 

      Nut (B) 

      Torque: 99 N*m (1010 kgf*cm, 73 ft.*lbf) 

    7. Install the 7 hole plugs to the front frame assembly.

      HINT: 

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

  16. INSTALL STEERING LINK ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 3

  17. INSTALL FRONT STABILIZER BAR (for AWD) 

    Refer to PROCEDURE - Step 4

  18. INSTALL FRONT NO. 1 STABILIZER BRACKET LH (for AWD) 

    Refer to PROCEDURE - Step 7

  19. INSTALL FRONT NO. 1 STABILIZER BRACKET RH (for AWD) 

    HINT: 

    Perform the same procedure as for the LH side.

  20. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY 

    Refer to PROCEDURE - Step 2

  21. INSTALL V-RIBBED BELT 

    See step  1

  22. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on the engine lifter.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.
      • Do not place any height adjustment attachments or plate lift attachments under the front frame assembly.
      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.
      • To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle.
    2. Remove the engine hangers.

      See step  83

    3. Install the engine assembly with transaxle to the vehicle.
      NOTE:
      • Do not raise the engine assembly with transaxle more than necessary. If the engine assembly with transaxle is raised excessively, the vehicle may also be lifted up.
      • 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 frame side plate RH and frame side plate LH with the 6 bolts and 2 nuts.

      Bolt (A) 

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      Bolt (B) and Nut (A) 

      Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) 

      GTY429927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    5. Install the front suspension member rear brace RH and front suspension member rear brace LH with the 6 bolts and 2 nuts.

      Bolt (C) 

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      Bolt (D) and Nut (B) 

      Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) 

      HINT: 

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

      Refer to INITIALIZATION [12/2013 - 11/2016]

  23. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for 2WD) 

    Refer to PROCEDURE - Step 13 , or refer to PROCEDURE - Step 13

  24. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for AWD) 

    Refer to PROCEDURE - Step 19 , or refer to PROCEDURE - Step 19

  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 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) 

  27. CONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  28. CONNECT DISCHARGE HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  29. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY (for 2WD) 

    Refer to PROCEDURE - Step 14

  30. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 10

  31. INSTALL FRONT DRIVE SHAFT ASSEMBLY 

    Refer to INSTALLATION [12/2013 - 11/2016]

  32. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 8

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

    Refer to PROCEDURE - Step 9

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

    Refer to PROCEDURE - Step 13

  35. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) 

    Refer to INSTALLATION [12/2013 - 11/2016]

  36. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Install a new clip to the No. 1 transmission control cable bracket.
    2. Install the transmission control cable assembly to the No. 1 transmission control cable bracket.
      GTY432378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw (A)
      *b Claw (B)
      *c Transmission Control Cable Assembly
      NOTE:
      • Make sure that the claws (A) on the clip are securely fit into the No. 1 transmission control cable bracket holes.
      • Make sure that the transmission control cable assembly is securely installed inside of the claws (B) of the clip.
    3. Install the transmission control cable assembly to the transmission control shaft lever with the nut.

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

      NOTE:

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

  37. CONNECT ENGINE WIRE 
    1. Engage the 2 wire harness clamps.
    2. Push down the lock lever to connect the ECM connector.
      GTY454636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • When connecting the ECM connector, make sure that dirt, water or other foreign matter do not contact the connecting part of the ECM connector.
      • Be sure to securely connect the ECM connectors.
    3. Connect the engine wire to the engine room relay block assembly.
    4. Connect the 4 connectors and install the engine wire to the engine room relay block assembly with the nut.

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

    5. Connect the 3 wire clamps.
    6. Install the 2 earth wires with the 2 bolts.

      Torque: 8.4 N*m (86 kgf*cm, 6 ft.*lbf) 

    7. Install the No. 1 relay block cover to the engine room relay block assembly.
  38. INSTALL STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  39. CONNECT NO. 1 INLET OIL COOLER HOSE 
    1. Connect the No. 1 inlet oil cooler hose and slide the clip to secure it.
  40. CONNECT NO. 1 OUTLET OIL COOLER HOSE 
    1. Connect the No. 1 outlet oil cooler hose and slide the clip to secure it.
  41. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Push the fuel tube connector onto the fuel main tube until the fuel tube connector makes a "click" sound.
      NOTE:
      • Check that there is no damage or foreign matter on the fuel tube connector.
      • After connecting, check that the fuel tube connector and the fuel main tube are securely connected by pulling on them.
    2. Install the No. 1 fuel pipe clamp.
  42. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose to the water outlet and slide the clip to secure it.
  43. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose to the water inlet and slide the clip to secure it.
  44. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.
  45. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the radiator pipe clamp.
    2. Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.
  46. CONNECT UNION TO CHECK VALVE HOSE 
    1. Connect the union to check valve hose to the intake air surge tank and slide the clip to secure it.
  47. 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.
  48. INSTALL ENGINE MOVING CONTROL ROD 

    HINT: 

    Perform this procedure only when replacement of the engine moving control rod or No. 3 engine mounting stay RH is necessary.

    1. Temporarily install the No. 3 engine mounting stay RH and engine moving control rod to the engine moving control rod bracket with the 2 bolts.
      GTY440156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Engine Moving Control Rod
      *2 No. 3 Engine Mounting Stay RH
      *3 Engine Moving Control Rod Bracket
    2. Tighten the bolt (A).

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

  49. INSTALL ENGINE MOVING CONTROL ROD BRACKET 
    1. When replacing the engine moving control rod or No. 3 engine mounting stay RH.
      GTY441685Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

        Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

        NOTE:

        Temporarily tighten the bolt (A) and (B), and then fully tighten the 4 bolts in the order of (C), (D), (A) and (B).

      2. Tighten the bolt (E).

        Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

    2. When not replacing the engine moving control rod or No. 3 engine mounting stay RH.
      GTY436215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

        Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

        NOTE:

        Temporarily tighten the bolt (A) and (B), and then fully tighten the 4 bolts in the order of (C), (D), (A) and (B).

  50. INSTALL NO. 2 ENGINE MOUNTING STAY RH 
    1. Install the No. 2 engine mounting stay RH with the bolt.

      Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

    2. Tighten the 2 nuts.

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

  51. INSTALL RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 14

  52. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 15

  53. INSTALL BATTERY 
    1. Install the battery and battery tray.
    2. Install the battery clamp and battery clamp bolt with the bolt and nut.

      Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

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

      Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) 

  54. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Install the air cleaner case sub-assembly with the 2 bolts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

  55. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
    1. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.
  56. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 3

  57. INSTALL INLET AIR CLEANER ASSEMBLY 
    1. Install the inlet air cleaner assembly with the 2 bolts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    2. Connect the 2 vacuum hose clamps to the inlet air cleaner assembly.
  58. INSPECT VACUUM HOSES 
    1. Visually check the vacuum hoses.
      GTY443356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    1. Connect the cable to the negative (-) battery terminal.

      Torque: 6.5 N*m (66 kgf*cm, 58 in.*lbf) 

      NOTE:

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

      Refer to INITIALIZATION [12/2013 - 11/2016]

  60. INSTALL FRONT WHEELS 

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

  61. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 4

  62. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 3

  63. ADD AUTOMATIC TRANSAXLE FLUID (for 2WD) 

    Refer to ADJUSTMENT [12/2013 - 11/2016]

  64. ADD AUTOMATIC TRANSAXLE FLUID (for AWD) 

    Refer to ADJUSTMENT [12/2013 - 11/2016]

  65. ADD TRANSFER OIL (for AWD) 

    Refer to PROCEDURE - Step 2

  66. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  67. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  68. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 4

  69. INSPECT ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1

  70. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK 

    Refer to PROCEDURE - Step 2

  71. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  72. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  73. INSPECT FOR OIL LEAK 
  74. INSPECT FOR EXHAUST GAS LEAK 
  75. INSPECT IGNITION TIMING 

    See step  8

  76. INSPECT ENGINE IDLE SPEED 

    See step  9

  77. INSPECT CO/HC 

    See step  11

  78. CHECK FOR SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [12/2013 - 11/2016]

  79. INSPECT SHIFT LEVER POSITION (for 2WD) 

    Refer to PROCEDURE - Step 1

  80. INSPECT SHIFT LEVER POSITION (for AWD) 

    Refer to PROCEDURE - Step 1

  81. ADJUST SHIFT LEVER POSITION (for 2WD) 

    Refer to PROCEDURE - Step 4

  82. ADJUST SHIFT LEVER POSITION (for AWD) 

    Refer to PROCEDURE - Step 4

  83. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [12/2013 - 11/2016]

  84. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Engage the 3 retainers to install the V-bank cover sub-assembly.
  85. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 4

  86. INSTALL RADIATOR SIDE SEAL RH 

    Refer to PROCEDURE - Step 5

  87. INSTALL RADIATOR SIDE DEFLECTOR SEAL LH 

    Refer to PROCEDURE - Step 6

  88. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 10 , or refer to PROCEDURE - Step 10

  89. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [12/2013 - ]

  90. INSTALL FRONT FENDER APRON SEAL LH 
    1. Install the front fender apron seal LH with the 2 bolts and clip.
  91. INSTALL FRONT FENDER APRON SEAL RH 
    1. Install the front fender apron seal RH with the 2 bolts and clip.
  92. INSTALL FRONT FENDER LINER LH 
    1. Install the front fender liner LH with the 3 screws and 3 clips.
  93. INSTALL FRONT FENDER LINER RH 
    1. Install the front fender liner RH with the 3 screws and 3 clips.
  94. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 16

  95. INSTALL NO. 2 ENGINE UNDER COVER 
    1. Install the No. 2 engine under cover with the 2 bolts, 2 screws and clip.
  96. INSTALL NO. 1 ENGINE UNDER COVER 
    1. Install the No. 1 engine under cover with the 8 bolts, 6 screws and 3 clips.
scientia non olet · About LEMON Manuals