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Installation [11/2023 - ]: Procedure

WARNING: This page is about a different car, the 2025 Toyota Highlander, 2024 Toyota Highlander, and 2023 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting bracket sub-assembly LH is necessary.

    1. GTY1103260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the engine mounting bracket sub-assembly LH with the 4 bolts.

        Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

        NOTE:

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

  2. INSTALL ENGINE MOUNTING SPACER 

    HINT: 

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

    1. GTY1105486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the engine mounting spacer to the vehicle body with the 2 bolts.

        Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

        NOTE:

        Temporarily tighten the bolt (A), and then fully tighten the 2 bolts in the order of (B) and (A).

  3. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 

    HINT: 

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

    1. Fig 1: Engine Mounting Insulator Sub-Assembly RH Bolts And Nut Tightening Sequence
      GTY1106765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the engine mounting insulator sub-assembly RH with the 2 bolts and nut.

        Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

        NOTE:

        Temporarily tighten the bolt (A), and then fully tighten the 2 bolts and nut in the order of (B), (A) and (C).

      2. Connect the No. 2 earth wire to the engine mounting insulator sub-assembly RH with the bolt.

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

      3. Connect the radiator reserve tank assembly with the bolt and nut in the order shown in the illustration.

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

      4. Engage the 3 clamps.
      5. Engage the 2 clamps.
      6. Install the intercooler reserve tank bracket with the bolt.

        Torque: 14 N.m (143 kgf/cm, 10 ft.lbf) 

  4. CONNECT INTERCOOLER RESERVE TANK ASSEMBLY 

    HINT: 

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

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

  5. INSTALL ENGINE HANGERS 

    Refer to PROCEDURE - Step 50

  6. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND 
  7. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    NOTE:
    • Do not apply or add any oil or grease to the belt tensioner to prevent abnormal noises from the belt tensioner pulley, belt squealing, etc.
    • Do not allow oil or grease to adhere to the moving parts of the belt tensioner, as this may cause malfunctions.
    GTY743260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  8. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY 

    Refer to PROCEDURE - Step 2

  9. INSTALL GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  10. INSTALL V-RIBBED BELT 

    Refer to PROCEDURE - Step 1

  11. INSTALL ENGINE WIRE 

    HINT: 

    As the illustration shown is an example, the actual details may differ.

    1. GTY1108943Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE 

    Refer to PROCEDURE - Step 2

  13. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  14. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 20

  15. INSTALL ENGINE MOUNTING INSULATOR LH 

    HINT: 

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

    Refer to PROCEDURE - Step 10

  16. INSTALL REAR ENGINE MOUNTING INSULATOR (for 2WD) 

    Refer to PROCEDURE - Step 3

  17. INSTALL REAR ENGINE MOUNTING INSULATOR (for AWD) 

    Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

  18. INSTALL FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

  19. INSTALL FRONT FRAME ASSEMBLY 

    Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

  20. CONNECT ENGINE WIRE 

    Refer to PROCEDURE - Step 23

  21. INSTALL STEERING GEAR HEAT INSULATOR 

    Refer to PROCEDURE - Step 7

  22. INSTALL NO. 2 RADIATOR HOSE 
    1. GTY1104566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2 to 7 mm (0.0787 to 0.276 in.) *b Paint Mark
      *c 120°(Claw of Clip Location) *d Upper Side
      *e RH Side *f Stopper
      1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 2 radiator hose until it contacts the stopper.
        • Make sure that the claws of the clip are within the location shown in the illustration.
      2. Engage the clamp.
  23. INSTALL WATER BY-PASS HOSE ASSEMBLY 
    1. GTY1105147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2 to 7 mm (0.0787 to 0.276 in.) *b Paint Mark
      *c 60°(Claw of Clip Location) *d Upper Side
      *e LH Side *f Front Side
      *g View A *h View B
      *i View C *j View D
      1. Connect the water by-pass hose assembly to the water control valve, front water by-pass joint and transmission oil cooler and slide the 4 clips to secure it.
        NOTE:
        • Make sure to slide the water by-pass hose assembly until it contacts the stopper.
        • Make sure that the claws of the clip are within the location shown in the illustration.
      2. Engage the clamp.
  24. CONNECT BREATHER PLUG HOSE 
  25. CONNECT VACUUM HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 26

  26. INSTALL STARTER ASSEMBLY 

    w/ Stop And Start System: Refer to PROCEDURE - Step 1

    w/o Stop And Start System: Refer to PROCEDURE - Step 1

  27. INSTALL FLYWHEEL HOUSING SIDE COVER 

    w/ Stop And Start System: Refer to PROCEDURE - Step 2

    w/o Stop And Start System: Refer to PROCEDURE - Step 2

  28. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 

    Refer to PROCEDURE - Step 29

  29. INSTALL FLYWHEEL HOUSING UNDER COVER 
  30. INSTALL CONVERTER WITH CATALYST ASSEMBLY 

    Refer to INSTALLATION [10/2022 - ]

  31. 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, keep the engine assembly with transaxle level.
      • 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.
      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments under the No. 2 oil pan sub-assembly of the engine assembly with transaxle.
    2. GTY1103790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger
      1. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and engine mounting bracket RH.
      2. Install the engine mounting bracket cap.
    3. GTY1109329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Bumper Extension Sub-assembly LH *2 Front Bumper Extension Sub-assembly RH
      *3 Front Suspension Member Brace Rear LH *4 Front Suspension Member Brace Rear RH
      Bolt Nut
      1. Operate the engine lifter and install the engine assembly with transaxle to the vehicle.
        WARNING:

        Do not raise the engine assembly with transaxle more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

        NOTE:
        • 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.
      2. Install the front bumper extension sub-assembly RH and front bumper extension sub-assembly LH to the front frame assembly and vehicle body with the 2 bolts (A), 2 bolts (B) and 4 nuts.

        Bolt (A) 

        Torque: 135 N.m (1377 kgf/cm, 100 ft.lbf) 

        Bolt (B) 

        Torque: 9.5 N.m (97 kgf/cm, 84 in.lbf) 

        Nut 

        Torque: 12.5 N.m (127 kgf/cm, 9 ft.lbf) 

      3. Install the front suspension member brace rear RH and front suspension member brace rear LH to the front frame assembly and vehicle body with the 2 bolts (C) and 4 bolts (D).

        Bolt (C) 

        Torque: 135 N.m (1377 kgf/cm, 100 ft.lbf) 

        Bolt (D) 

        Torque: 62 N.m (632 kgf/cm, 46 ft.lbf) 

      4. Install the engine mounting insulator LH to the engine mounting bracket sub-assembly LH with the bolt and nut.

        Torque: 42 N.m (428 kgf/cm, 31 ft.lbf) 

      5. Install the wire harness clamp bracket to the engine mounting insulator LH with the bolt.

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

      6. Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 3 bolts and nut.

        Bolt 

        Torque: 72 N.m (734 kgf/cm, 53 ft.lbf) 

        Nut 

        Torque: 42 N.m (428 kgf/cm, 31 ft.lbf) 

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

      Refer to INITIALIZATION [10/2022 - ]

  32. INSTALL FRONT DRIVE SHAFT ASSEMBLY 

    Refer to INSTALLATION [10/2022 - ]

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

    Refer to INSTALLATION [10/2022 - ]

  34. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for 2WD) 

    Refer to INSTALLATION [10/2022 - ]

  35. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 11

  36. CONNECT NO. 5 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 6

  37. CONNECT WIRE HARNESS 

    Bolt (Vehicle Body) 

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

    Bolt (Automatic Transaxle Assembly) 

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

    Nut 

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

  38. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 3

  39. CONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  40. CONNECT NO. 2 INTERCOOLER COOLING WATER HOSE 
    1. GTY1107875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2 to 7 mm (0.0787 to 0.276 in.) *b Paint Mark
      *c 75°(Claw of Clip Location) *d 60°(Claw of Clip Location)
      *e Upper Side *f Rear Side
      *g View A - -
      1. Connect the No. 2 intercooler cooling water hose to the No. 2 intercooler cooling water pipe and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 2 intercooler cooling water hose until it contacts the stopper.
        • Make sure that the claws of the clip are within the location shown in the illustration.
      2. Engage the clamp.
  41. CONNECT NO. 1 INTERCOOLER COOLING WATER HOSE 

    Refer to PROCEDURE - Step 12

  42. CONNECT NO. 2 RADIATOR HOSE 
    1. GTY1105703Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°(Claw of Clip Location)
      *c Paint Mark *d Upper Side
      *e RH Side *f 2 to 5 mm (0.0787 to 0.197 in.)
      1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 2 radiator hose until it contacts the stopper.
        • Make sure that the claws of the clip are within the location shown in the illustration.
      2. Engage the clamp to connect the No. 2 radiator hose to the fan with motor assembly.
  43. CONNECT NO. 1 RADIATOR HOSE 
    1. GTY1109091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2 to 7 mm (0.0787 to 0.276 in.) *b Paint Mark
      *c 120°(Claw of Clip Location) *d Upper Side
      *e LH Side *f View A
      1. Connect the No. 1 radiator hose to the water control valve and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 1 radiator hose until it contacts the stopper.
        • Make sure that the claws of the clip are within the location shown in the illustration.
  44. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. GTY1107938Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the fuel tube sub-assembly.

        Refer to PRECAUTION [10/2022 - ]

      2. Install the EFI fuel pipe clamp (fuel tube sub-assembly side) to the fuel tube connector.
  45. CONNECT OUTLET HEATER WATER HOSE B 
    1. GTY1105314Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2 to 7 mm (0.0787 to 0.276 in.) *b 120°(Claw of Clip Location)
      *c Front Side *d Upper Side
      *e View A - -
      1. Connect the heater water hose to the No. 2 water by-pass pipe and slide the clip to secure it.
        NOTE:
        • Make sure to slide the heater water hose until it contacts the stopper.
        • Make sure that the claws of the clip are within the location shown in the illustration.
      2. Engage the clamp.
  46. CONNECT INLET HEATER WATER HOSE B 
    1. GTY1108917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2 to 7 mm (0.0787 to 0.276 in.) *b 360°(Claw of Clip Location)
      *c Front Side *d Upper Side
      *e View A - -
      1. Connect the inlet heater water hose to the water control valve and slide the clip to secure it.
        NOTE:
        • Make sure to slide the inlet heater water hose until it contacts the stopper.
        • Make sure that the claws of the clip are within the location shown in the illustration.
  47. CONNECT VACUUM HOSE ASSEMBLY 
  48. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY 
  49. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    NOTE:

    Before connecting the transmission control cable assembly, check that the shift lever is in N.

    1. GTY1104344Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Transmission Control Shaft Lever - -
      *a N *b Manual Valve Link Lever Sub-assembly
      *c Manual Valve *d Correct
      *e Incorrect - -
      1. Turn the transmission control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.
        NOTE:

        If the transmission control shaft lever is turned counterclockwise more than necessary, manual valve link lever sub-assembly may separate from the manual valve.

      2. Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.
      3. Connect the transmission control cable assembly to the transmission control shaft lever as shown in the illustration.
  50. INSTALL BATTERY CLAMP SUB-ASSEMBLY 

    Bolt 

    Torque: 18.5 N.m (189 kgf/cm, 14 ft.lbf) 

    Nut 

    Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  51. INSTALL ECM 

    Refer to PROCEDURE - Step 3

  52. INSTALL AIR CLEANER HOSE ASSEMBLY 
    1. GTY1106210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion *b Cutout
      *c Top *d 6 to 14 mm (0.236 to 0.551 in.)
      1. Install the air cleaner hose assembly to the inlet compressor elbow sub-assembly.
        NOTE:

        Align the cutout of the air cleaner hose assembly with the protrusion of the inlet compressor elbow sub-assembly.

      2. Tighten the hose clamp in the position shown in the illustration.
        NOTE:

        Make sure that the end of the hose clamp is positioned as shown in the illustration.

  53. CONNECT NO. 2 VENTILATION HOSE 
    1. GTY1106351Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Top *b LH Side
      *c 45°(Claw of Clip Location) *d 25°(Claw of Clip Location)
      *e Paint Mark - -
      1. Connect the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.
        NOTE:

        Make sure to position the clip as shown in the illustration.

  54. INSTALL AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 4

  55. INSTALL AIR CLEANER HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 5

  56. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. GTY1107410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Cylinder *b Bolt
      1. Align the 3 grommets of the No. 1 engine cover sub-assembly with the 2 cylinders and bolt as shown in the illustration, then push the No. 1 engine cover sub-assembly downward to install it.
  57. INSPECT VACUUM HOSES 
    1. GTY1104945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for 2WD *B for AWD
      1. Inspect the vacuum hoses.
  58. INSTALL BATTERY 

    Refer to INSTALLATION [11/2023 - ]

  59. INSTALL NO. 2 FRONT BUMPER REINFORCEMENT 

    for Sport Package: Refer to PROCEDURE - Step 3

    except Sport Package: Refer to PROCEDURE - Step 3

  60. INSTALL FRONT BUMPER LOWER ABSORBER 

    for Sport Package: Refer to PROCEDURE - Step 5

    except Sport Package: Refer to PROCEDURE - Step 5

  61. INSTALL FRONT BUMPER ASSEMBLY 

    for Sport Package: Refer to INSTALLATION [09/2020 - ]

    except Sport Package: Refer to INSTALLATION [09/2020 - ]

  62. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 5

  63. ADD TRANSFER OIL (for AWD) 

    Refer to PROCEDURE - Step 3

  64. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  65. ADD COOLANT (for Intercooler) 

    Refer to PROCEDURE - Step 5

  66. ADD SPECIFIED AMOUNT OF AUTOMATIC TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 5

  67. ADJUST AUTOMATIC TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 6

  68. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  69. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  70. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  71. INSPECT FOR ENGINE OIL LEAK 

    Refer to PROCEDURE - Step 6

  72. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1

  73. INSPECT FOR COOLANT LEAK (for Intercooler) 

    Refer to PROCEDURE - Step 1

  74. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK 
  75. INSPECT FOR TRANSFER OIL LEAK (for AWD) 
  76. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 5

  77. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 3

  78. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1

  79. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK (for Engine) 

    Refer to PROCEDURE - Step 2

  80. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 13

  81. INSTALL FRONT FLOOR COVER RH 

    Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  82. INSTALL FRONT FENDER APRON SEAL LH 

    Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  83. INSTALL FRONT FENDER APRON SEAL RH 

    Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  84. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY 

    Bolt 

    Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  85. INSTALL NO. 1 ENGINE UNDER COVER 

    Bolt 

    Torque: 7.5 N.m (76 kgf/cm, 66 in.lbf) 

  86. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 
  87. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 
  88. INSTALL FRONT WHEELS 

    Refer to INSTALLATION [10/2022 - ]

  89. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  90. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [11/2023 - 11/2024] , or refer to ADJUSTMENT [11/2024 - ]

  91. INITIALIZATION AFTER RECONNECTING BATTERY TERMINAL 

    HINT: 

    When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.

    Refer to AUTOMATIC LEARNING CHART [11/2023 - ]

  92. PERFORM INITIALIZATION 

    Refer to INITIALIZATION [10/2022 - ]

  93. INSPECT IGNITION TIMING 

    Refer to PROCEDURE - Step 9

  94. INSPECT ENGINE IDLE SPEED 

    Refer to PROCEDURE - Step 10

  95. INSPECT CO/HC 

    Refer to PROCEDURE - Step 12

  96. CHECK SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [11/2023 - ]

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