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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 23 (Engine Mechanical System (A25A-FXS) - Service Information (2 Of 3)) >> Engine Assembly >> Installation [11/2023 - ] >> Procedure

Installation [11/2023 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH 

    HINT: 

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

    1. Install the engine mounting insulator sub-assembly LH 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).

      GTY888769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL ENGINE MOUNTING SPACER 

    HINT: 

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

    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).

      GTY933726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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. Install the engine mounting insulator sub-assembly RH with the 2 bolts and nut.
      GTY876769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.

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

    4. Engage the 2 clamps.
    5. Install the No. 1 inverter reserve tank bracket with the bolt.

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

  4. CONNECT INVERTER RESERVE TANK ASSEMBLY 
    1. Fit the pin of the inverter reserve tank assembly into the grommet as shown in the illustration.
      GTY848566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Grommet
    2. Connect the inverter reserve tank assembly with the 2 bolts.

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

  5. INSTALL ENGINE HANGERS 

    See step  40

  6. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND 
    1. Remove the engine assembly from the engine stand.
  7. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE 

    Refer to PROCEDURE - Step 2

  8. INSTALL FLYWHEEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  9. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY 

    Refer to PROCEDURE - Step 4

  10. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 14

  11. INSTALL REAR ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Align and insert the protrusion of the rear engine mounting bracket into the gap between the 2 inner walls of the rear engine mounting insulator to align the hole of the rear engine mounting bracket with the bolt hole of the rear engine mounting insulator, and install the rear engine mounting insulator with the bolt.

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

      GTY1103093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Rear Engine Mounting Bracket
      *2 Rear Engine Mounting Insulator
      *a Protrusion
      *b Hole
      *c Wall
      *d Gap
    2. Install the wire harness clamp to the rear engine mounting insulator with the bolt.

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

  12. INSTALL FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Install the front engine mounting insulator to the front engine mounting bracket with the bolt.

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

  13. INSTALL FRONT FRAME ASSEMBLY 

    Refer to PROCEDURE - Step 6

  14. INSTALL FLYWHEEL HOUSING SIDE COVER 

    Refer to PROCEDURE - Step 20

  15. INSTALL STARTER HOLE INSULATOR 

    Refer to PROCEDURE - Step 21

  16. INSTALL HEATER WATER HOSE (w/ Exhaust Heat Recirculation System) 
    1. Install the heater water hose to the flow shutting valve (water by-pass hose assembly) and slide the clip to secure it.
    2. Engage the clamp to connect the heater water hose.
  17. INSTALL HV AIR CONDITIONING WIRE 
    1. Engage the guide to install the HV air conditioning wire to the hybrid vehicle transaxle assembly.
    2. Install the 2 bolts.

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

    3. Connect the connector and slide the green-colored lock as shown in the illustration to lock it securely.
      WARNING:

      Make sure to wear insulated gloves.

      NOTE:

      Make sure that the connector is connected securely.

      GTY744925Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Green-colored Lock
      Slide
    4. Engage the 2 clamps.
  18. INSTALL ENGINE WIRE 
    1. Connect all connectors and clamps, and install the engine wire to the engine assembly with transaxle.
  19. INSTALL STEERING GEAR HEAT INSULATOR 

    Refer to PROCEDURE - Step 7

  20. INSTALL FLYWHEEL HOUSING UNDER COVER 
    1. Install the flywheel housing under cover to the cylinder block sub-assembly.
  21. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 

    HINT: 

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

    Refer to INITIALIZATION [10/2021 - ]

    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.
    2. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and engine mounting bracket RH.
    3. Install the fuel delivery guard to the engine mounting bracket RH with the bolt.

      Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf) 

    4. 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.
    5. 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.
      GTY937637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Bolt (A) 

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

      Bolt (B) 

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

      Nut 

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

    6. 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 4 bolts (C) and 2 bolts (D).

      Bolt (C) 

      Torque: 60 N*m (612 kgf*cm, 44 ft.*lbf) 

      Bolt (D) 

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

    7. Install the engine mounting insulator sub-assembly LH to the hybrid vehicle transaxle assembly with the 4 bolts.

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

      NOTE:

      Fully tighten the 4 bolts in the order of (A), (C), (B) and (D).

      GTY860648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Install the engine mounting stay LH to the engine mounting insulator sub-assembly LH with the 4 bolts.

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

      NOTE:

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

      GTY875132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. 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) 

  22. CONNECT HEATER WATER HOSE (w/ Exhaust Heat Recirculation System) 
    1. Connect the heater water hose to the No. 1 air conditioning accessory assembly and slide the clip to secure it.
  23. INSTALL FRONT DRIVE SHAFT ASSEMBLY 

    Refer to INSTALLATION [12/2019 - ]

  24. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 

    Refer to PROCEDURE - Step 7

  25. INSTALL FRONT FLOOR COVER LH 
    1. Engage the 5 clamps to install the front floor cover LH to the vehicle body with the 5 bolts, 3 screws and 3 clips.

      Bolt 

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

  26. INSTALL FRONT FLOOR COVER RH 
    1. Engage the 4 clamps to install the front floor cover RH to the vehicle body with the 3 bolts, 3 screws and clip.

      Bolt 

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

  27. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 11

  28. CONNECT NO. 4 WATER BY-PASS HOSE 
    1. Connect the No. 4 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.
      GTY930326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c Upper Side *d Front Side
      *e 2 to 7 mm (0.0787 to 0.276 in.) - -
  29. CONNECT WIRE HARNESS 
    1. Connect the earth wire with the 2 bolts.

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

    2. Engage the claw to connect the wire harness to the No. 1 engine room relay block and No. 1 junction block assembly.
    3. Connect the 4 connectors to the No. 1 engine room relay block and No. 1 junction block assembly.
    4. Install the nut to the No. 1 engine room relay block and No. 1 junction block assembly.

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

    5. Engage the 3 claws and install the No. 1 relay block cover to the No. 1 engine room relay block and No. 1 junction block assembly.
  30. CONNECT NO. 5 INVERTER COOLING HOSE 
    1. Connect the No. 5 inverter cooling hose to the motor cooling cooler and slide the clip to secure it.
      GTY945440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c Paint Mark *d Upper Side
      *e Front Side - -
  31. CONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  32. CONNECT DISCHARGE HOSE SUB-ASSEMBLY 
    1. Remove the vinyl tape from the discharge hose sub-assembly.
    2. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor with motor assembly.

      Compressor Oil

      ND-OIL 11 or equivalent

    3. Install the O-ring to the discharge hose sub-assembly.
      NOTE:
      • Keep the O-ring and O-ring fitting surface free of foreign matter.
      • Do not use any compressor oil other than ND-OIL 11 or equivalent. If any compressor oil other than ND-OIL 11 or equivalent is used, compressor motor insulation performance may decrease, resulting in leakage of electric power.
    4. Connect the discharge hose sub-assembly to the compressor with motor assembly with the bolt.

      Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

  33. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the water inlet with thermostat sub-assembly and slide the clip to secure it.
      GTY920456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c Paint Mark *d Upper Side
      *e RH Side *f 2 to 7 mm (0.0787 to 0.276 in.)
  34. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.
      GTY1181099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A *b 120°
      *c Paint Mark *d Front Side
      *e RH Side *f 2 to 7 mm (0.0787 to 0.276 in.)
    2. Engage the clamp.
  35. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube sub-assembly.
      1. Connect the fuel tube sub-assembly to the fuel pipe.

        Refer to PRECAUTION [11/2023 - ]

    2. Install the No. 1 fuel pipe clamp to the fuel tube connector.
  36. CONNECT INLET HEATER WATER HOSE B 
    1. Align the protrusions of the inlet heater water hose B connector with the cutouts in the flow shutting valve (water by-pass hose assembly) and securely insert the inlet heater water hose B connector into the stopper of the pipe.
      GTY767363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Push in the retainer.
      GTY845819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Push
      Push in
    3. Check that the flow shutting valve (water by-pass hose assembly) and inlet heater water hose B connector are securely connected by pulling on them.
  37. CONNECT OUTLET HEATER WATER HOSE B 
    1. Align the protrusion of the No. 2 water by-pass pipe sub-assembly with the cutout in the outlet heater water hose B connector and securely insert the outlet heater water hose B connector into the stopper of the pipe.
      GTY765348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
    2. Push in the retainer.
      GTY926583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Push
      Push in
    3. Check that the No. 2 water by-pass pipe sub-assembly and outlet heater water hose B connector are securely connected by pulling on them.
  38. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY 
    1. Connect the fuel vapor feed hose assembly to the No. 1 vacuum switching valve assembly and slide the clip to secure it.
    2. Engage the clamp.
  39. INSTALL INVERTER WITH CONVERTER ASSEMBLY 

    Refer to INSTALLATION [11/2023 - ]

  40. INSTALL NO. 2 FRONT BUMPER REINFORCEMENT 

    Refer to PROCEDURE - Step 3

  41. INSTALL FRONT BUMPER LOWER ABSORBER 

    Refer to PROCEDURE - Step 5

  42. INSTALL HEADLIGHT ASSEMBLY LH 

    Refer to INSTALLATION [09/2020 - ]

  43. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 5

  44. ADD HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 6

  45. ADD ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  46. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  47. WARM UP COMPRESSOR 

    Refer to PROCEDURE - Step 4

  48. INSPECT SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 2

  49. ADJUST SHIFT LEVER POSITION 

    Refer to ADJUSTMENT [12/2019 - ]

  50. INSPECT FOR ENGINE OIL LEAK 

    Refer to PROCEDURE - Step 6

  51. INSPECT FOR COOLANT LEAK (for Engine) 

    Refer to PROCEDURE - Step 1

  52. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 5

  53. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  54. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 6

  55. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1

  56. INSPECT HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 5

  57. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK 

    Refer to PROCEDURE - Step 2

  58. INSTALL FRONT FENDER APRON SEAL LH 
    1. Install the front fender apron seal LH with the 2 bolts and clip.

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

  59. INSTALL FRONT FENDER APRON SEAL RH 
    1. Install the front fender apron seal RH with the 2 bolts and clip.

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

  60. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY 
    1. Install the No. 2 engine under cover assembly with the 2 bolts, 2 screws and 6 clips.

      Bolt 

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

  61. INSTALL NO. 1 ENGINE UNDER COVER 
    1. Install the No. 1 engine under cover with the 3 bolts, 8 screws and 2 clips.

      Bolt 

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

  62. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 
    1. Install the front wheel opening extension pad LH with the 4 screws.
  63. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 
    1. Install the front wheel opening extension pad RH with the 4 screws.
  64. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Engage the 3 clips to install the No. 1 engine cover sub-assembly.
      GTY880638Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Securely engage the clips.
      • If the clips are forcibly engaged or struck with an object, they may be damaged.
  65. INSTALL FRONT WHEELS 

    Refer to INSTALLATION [10/2022 - ]

  66. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  67. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

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

  68. PERFORM INITIALIZATION 

    Refer to PROCEDURE - Step 9

  69. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL 

    HINT: 

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

    Refer to AUTOMATIC LEARNING CHART [11/2023 - ]

  70. INSPECT IGNITION TIMING 

    Refer to PROCEDURE - Step 7

  71. INSPECT ENGINE IDLE SPEED 

    Refer to PROCEDURE - Step 8

  72. INSPECT CO/HC 

    Refer to PROCEDURE - Step 10

  73. CHECK SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [11/2023 - ]

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