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Installation [02/2014 - 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 COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1

  2. INSTALL KNOCK CONTROL SENSOR WIRE 
    1. Engage the 3 clamps and install the knock control sensor wire to the engine assembly.
  3. INSTALL KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 1

  4. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 

    Refer to PROCEDURE - Step 1

  5. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 1

  6. INSTALL WATER PUMP PULLEY 
    1. Temporarily install the water pump pulley with the 4 bolts.
    2. Using SST, hold the water pump pulley.
      • SST: 09960-10010 
        1. 09962-01000
        2. 09963-00700
    3. Tighten the 4 bolts.

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

  7. INSTALL NO. 2 TIMING GEAR COVER 
    1. Install the No. 2 timing gear cover with the 2 bolts.

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

  8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.
      GTY424628Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt (A)
      Bolt (B)

      HINT: 

      Each bolt length is as follows:

      Item Length
      Bolt (A) 70 mm (2.76 in.)
      Bolt (B) 33 mm (1.30 in.)
    2. Install the V-ribbed belt tensioner assembly by tightening the bolt (1) and then the bolt (2).

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

    3. Tighten the other bolts.

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

  9. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 2

  10. INSTALL NO. 2 ENGINE MOUNTING STAY RH (for Intake Manifold Side) 

    Refer to PROCEDURE - Step 5

  11. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  12. INSTALL EGR DELIVERY CHAMBER 

    Refer to PROCEDURE - Step 7

  13. INSTALL REAR ENGINE MOUNTING BRACKET 
    1. Install the rear engine mounting bracket with the 3 bolts.

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

  14. INSTALL ENGINE MOUNTING BRACKET RH 
    1. Install the engine mounting bracket RH with the 3 bolts.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

  15. INSTALL EXHAUST MANIFOLD TO HEAD GASKET LH 

    Refer to PROCEDURE - Step 1

  16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 2

  17. INSTALL NO. 2 MANIFOLD STAY 

    Refer to PROCEDURE - Step 3

  18. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 4

  19. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Install a new O-ring to the No. 2 engine oil level dipstick guide.
    2. Apply a light coat of engine oil to the O-ring.
    3. Push the No. 2 engine oil level dipstick guide end into the engine oil level dipstick guide.
    4. Install the bolt.

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

    5. Install the engine oil level dipstick.
  20. INSTALL EXHAUST MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 9

  21. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 10

  22. INSTALL NO. 1 EGR PIPE 

    Refer to PROCEDURE - Step 11

  23. INSTALL EGR COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  24. INSTALL NO. 2 EGR PIPE 

    Refer to PROCEDURE - Step 2

  25. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 11

  26. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  27. INSTALL V-RIBBED BELT 

    See step  1

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