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Home >> Toyota >> 2019 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 11 (Engine Mechanical (1AR-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 variant/trim than selected.
  1. INSTALL ENGINE HANGERS 

    See step  64

  2. REMOVE ENGINE FROM ENGINE STAND 
    1. Using an engine sling device and engine lift, secure the engine assembly.
      NOTE:
      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.
      • 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 

    Refer to PROCEDURE - Step 7

  5. 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) 

  6. INSTALL DRIVE SHAFT BEARING BRACKET 
    1. Install the drive shaft bearing bracket with the 3 bolts.

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

  7. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Temporarily install the front engine mounting insulator with the 3 nuts.
  8. 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.
  9. 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.
  10. INSTALL FRONT FRAME ASSEMBLY 
    1. Install the engine mounting insulator LH with the nut.

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

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

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

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

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

    4. Fully tighten the 9 temporarily installed nuts of the engine mounting insulators.
      GTY441229Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Engine Mounting Insulator *2 Engine Mounting Insulator RH
      *3 Engine Mounting Insulator LH - -

      HINT: 

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

      Nut (A) 

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

      Nut (B) 

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

    5. Install the 5 hole plugs.
      GTY438764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Engine Mounting Insulator *2 Engine Mounting Insulator RH
      *3 Engine Mounting Insulator LH - -

      HINT: 

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

  11. INSTALL GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  12. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY 

    Refer to PROCEDURE - Step 2

  13. INSTALL V-RIBBED BELT 

    See step  1

  14. INSTALL ENGINE WIRE 
    1. Install the engine wire to the engine assembly with transaxle.
  15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on an 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.
      • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.
      • 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.
    2. Remove the engine hangers.

      See step  78

    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 rail plate RH and frame side rail plate LH with the 6 bolts and 2 nuts.
      GTY429925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      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) 

    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 - ]

  16. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 

    Refer to PROCEDURE - Step 12

  17. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover.
  18. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 14

  19. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH 

    Refer to PROCEDURE - Step 1

  20. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 2

  21. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH 

    Refer to PROCEDURE - Step 3

  22. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  23. CONNECT TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 1

  24. CONNECT TIE ROD ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  25. INSTALL FRONT SPEED SENSOR 

    Refer to PROCEDURE - Step 19

  26. INSTALL FRONT STABILIZER LINK ASSEMBLY 

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

  27. INSTALL FRONT AXLE SHAFT NUT 

    Refer to PROCEDURE - Step 8

  28. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 7

  29. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  30. CONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  31. CONNECT DISCHARGE HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  32. CONNECT UNION TO VACUUM TUBE HOSE 
    1. Connect the 2 union to vacuum tube hoses to the No. 1 vacuum hose assembly and slide the 2 clips to secure them.
  33. INSTALL ENGINE MOVING CONTROL ROD 

    HINT: 

    Perform this procedure only when replacement of the engine moving control rod is necessary.

    1. Temporarily install the engine moving control rod to the engine moving control rod bracket with the bolt.
  34. INSTALL ENGINE MOVING CONTROL ROD BRACKET 
    1. When replacing the engine moving control rod sub-assembly or No. 3 engine mounting stay RH.
      1. Install the engine moving control rod bracket with engine moving control rod sub-assembly with the 4 bolts.

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

        NOTE:

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

        GTY443268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Tighten the bolt (E).

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

    2. When not replacing the engine moving control rod sub-assembly or No. 3 engine mounting stay RH.
      1. Install the engine moving control rod bracket with engine moving control rod sub-assembly with the 4 bolts.

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

        NOTE:

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

        GTY432221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL NO. 2 ENGINE MOUNTING STAY RH 
    1. Install the No. 2 engine mounting stay RH with the 2 bolts.

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

  36. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Connect the transmission control cable assembly to the No. 1 control cable bracket with a new clip.
      GTY438851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the transmission control cable assembly to the control shaft lever with the nut.
      GTY384496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  37. INSTALL NO. 1 AIR CLEANER BRACKET 
    1. Install the No. 1 air cleaner bracket to the battery carrier with the bolt.

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

    2. Connect the 2 wire clamps.
  38. CONNECT ENGINE WIRE 
    1. Engage the 2 wire harness clamps.
      GTY454636Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push down the lock lever to connect the ECM connector.
      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 earth wire with the bolt.

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

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

    Refer to PROCEDURE - Step 1

  40. CONNECT NO. 3 WATER BY-PASS HOSE 
    1. Connect the No. 3 water by-pass hose to the transmission oil cooler and slide the clip to secure it.
  41. CONNECT NO. 4 WATER BY-PASS HOSE 
    1. Connect the No. 4 water by-pass hose to the transmission oil cooler and slide the clip to secure it.
  42. CONNECT OUTLET HEATER WATER HOSE 
    1. Connect the outlet heater water hose B to the cylinder head sub-assembly and slide the clip to secure it.
    2. Engage the 2 claws to connect the inlet heater water hose and outlet heater water hose A.
  43. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose to the cylinder head sub-assembly 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 cylinder head sub-assembly and slide the clip to secure it.
    2. Connect the air fuel ratio sensor wire to the No. 1 radiator hose with the hose clamp.
  46. INSTALL BATTERY 
    1. Install the battery and battery tray.
    2. Install the battery clamp with the bolt and nut.

      Bolt 

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

      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) 

  47. INSTALL RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 14

  48. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 15

  49. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Insert the projection of the air cleaner case sub-assembly into the hole of the No. 1 air cleaner bracket as shown in the illustration.
      GTY441534Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hole
      *b Projection
    2. Install the 2 bolts.

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

  50. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
    1. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.
      NOTE:

      Install the air cleaner filter element sub-assembly with the printed side facing the vehicle front.

  51. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 4

  52. 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) 

  53. 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]

  54. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 4

  55. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 2

  56. ADD AUTOMATIC TRANSAXLE FLUID 

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

  57. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  58. WARM UP ENGINE 
  59. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  60. INSPECT FOR OIL LEAK 

    Refer to PROCEDURE - Step 5

  61. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  62. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 8

  63. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 4

  64. INSPECT IGNITION TIMING 

    See step  9

  65. INSPECT ENGINE IDLE SPEED 

    See step  10

  66. INSPECT CO/HC 

    See step  12

  67. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Engage the 3 pins to install the No. 1 engine cover sub-assembly.
  68. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 4

  69. INSTALL RADIATOR SIDE SEAL RH 

    Refer to PROCEDURE - Step 5

  70. INSTALL RADIATOR SIDE DEFLECTOR SEAL LH 

    Refer to PROCEDURE - Step 6

  71. INSPECT AND ADJUST SHIFT LEVER POSITION 

    Refer to ADJUSTMENT [12/2013 - ]

  72. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

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

  73. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to INSTALLATION [12/2013 - ]

  74. INSTALL BRAKE BOOSTER VACUUM EJECTOR 

    Refer to PROCEDURE - Step 18

  75. INSTALL FRONT FENDER APRON SEAL LH 
    1. Install the front fender apron seal LH with the 2 bolts and clip.
  76. INSTALL FRONT FENDER APRON SEAL RH 
    1. Install the front fender apron seal RH with the 2 bolts and clip.
  77. INSTALL FRONT FENDER LINER LH 
    1. Install the front fender liner LH with the 3 screws and 3 clips.
  78. INSTALL FRONT FENDER LINER RH 
    1. Install the front fender liner RH with the 2 screws and 3 clips.
  79. INSTALL FLOOR UNDER COVER LH 

    Refer to PROCEDURE - Step 8

  80. INSTALL NO. 2 ENGINE UNDER COVER 
    1. Install the No. 2 engine under cover with the 2 bolts, 2 screws and clip.
  81. INSTALL NO. 1 ENGINE UNDER COVER 
    1. Install the No. 1 engine under cover with the 6 bolts, 8 screws and 3 clips.
  82. INSTALL FRONT WHEEL 

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

  83. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

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

  84. INSPECT SPEED SENSOR SIGNAL 

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

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