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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical System (2GR-FKS) - Service Information (1 Of 2) >> Engine Assembly >> Installation [12/2019 - 09/2020] >> Procedure

Installation [12/2019 - 09/2020]: Procedure

  1. INSTALL ENGINE MOUNTING INSULATOR LH 

    HINT: 

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

  2. 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. Temporarily tighten the bolt (A), and then fully tighten the 4 bolts in the order of (B), (C), (D) and (A).
      GTY928873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      NOTE:

      Make sure that there is no gap between the engine mounting bracket sub-assembly LH and vehicle body before tightening the bolts.

  3. 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.
      GTY943109Courtesy 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 in the order of (B) and (A).

  4. 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 to the engine mounting spacer and vehicle body with the nut and 2 bolts.
      GTY942281Courtesy 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. Install the radiator reserve tank assembly with the bolt and nut in the order shown in the illustration.
      Fig 1: Radiator Reserve Tank Assembly Bolt And Nut Tightening Sequence
      GTY903688Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    4. Engage the 2 clamps.
  5. INSTALL ENGINE HANGERS 

    See step  61

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

    See step  2

  8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  3

  9. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 
  10. INSTALL FRONT ENGINE MOUNTING BRACKET 
  11. INSTALL REAR ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Install the rear engine mounting insulator to the front frame assembly with the 4 nuts.

      Torque: 72 N.m (734 kgf/cm, 53 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 frame assembly with the 3 nuts.

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

  13. INSTALL FRONT FRAME ASSEMBLY 
    1. Install the rear engine mounting insulator to the rear engine mounting bracket sub-assembly with the bolt.

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

    2. 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) 

  14. REMOVE ENGINE HANGERS 

    See step  70

  15. INSTALL ENGINE WIRE 
    1. Connect all connectors and clamps, and install the engine wire to the engine assembly with transaxle.
  16. CONNECT HOSE CLAMP 
  17. CONNECT WATER BY-PASS HOSE ASSEMBLY 
  18. INSTALL TRANSMISSION BREATHER CLAMP 
  19. INSTALL BREATHER PLUG HOSE 
  20. INSTALL STARTER ASSEMBLY 
  21. CONNECT VACUUM HOSE 
  22. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 

    HINT: 

    Perform Inspection After Repair after replacing the engine assembly.

    Refer to INITIALIZATION [12/2019 - 10/2022]

    1. Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front frame assembly level, set an engine lifter underneath the engine assembly with transaxle and front frame assembly.
      NOTE:
      • 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 engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.
    2. 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.
    3. 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 4 bolts and 4 nuts.
      GTY879849Courtesy 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) 

    4. 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 6 bolts.

      Bolt (C) 

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

      Bolt (D) 

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

    5. 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) 

    6. Install the engine mounting insulator sub-assembly RH to the front No. 1 engine mounting bracket LH 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) 

    7. Install the No. 2 engine mounting stay RH with the bolt and 2 nuts.

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

  23. INSTALL NO. 2 FRONT BUMPER REINFORCEMENT 

    Refer to PROCEDURE - Step 3

  24. INSTALL FRONT BUMPER LOWER ABSORBER 

    Refer to PROCEDURE - Step 5

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

    Refer to PROCEDURE - Step 28

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

    Refer to PROCEDURE - Step 30

  27. 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) 

  28. INSTALL FRONT DRIVE SHAFT ASSEMBLY 

    Refer to INSTALLATION [12/2019 - 10/2022]

  29. INSTALL EXHAUST MANIFOLD 

    Refer to INSTALLATION [12/2019 - 10/2022]

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

    Refer to INSTALLATION [12/2019 - 10/2022]

  31. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 12

  32. CONNECT OUTLET NO. 1 OIL COOLER HOSE 
    1. Connect the outlet No. 1 oil cooler hose to the oil cooler union sub-assembly and slide the clip to secure it.
  33. CONNECT NO. 3 TRANSMISSION OIL COOLER HOSE 
    1. Engage the clamp.
    2. Connect the No. 3 transmission oil cooler hose to the No. 1 oil cooler tube sub-assembly without hose and slide the clip to secure it.
  34. CONNECT ENGINE WIRE 
    1. Engage the 3 clamps.
    2. Engage the 2 clamps and connect the engine wire to the vehicle body.
    3. Connect the engine wire with the bolt.

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

    4. Engage the 2 clamps.
    5. Engage the claw and connect the engine wire to the engine room relay block and junction block assembly.
    6. Install the nut to the engine room relay block and junction block assembly.

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

    7. Connect the 5 connectors to the engine room relay block and junction block assembly.
    8. Install the No. 1 relay block cover to the engine room relay block and junction block assembly.
  35. CONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  36. CONNECT DISCHARGE HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  37. CONNECT NO. 1 FUEL HOSE 
    1. Connect the No. 1 fuel hose (for Port Injection).
      1. Connect the No. 1 fuel hose to the fuel pipe.

        Refer to PRECAUTION [12/2019 - 10/2022]

    2. Connect the No. 1 fuel hose (for Direct Injection).
      1. Connect the No. 1 fuel hose to the fuel pipe.

        Refer to PRECAUTION [12/2019 - 10/2022]

    3. Install the No. 1 fuel pipe clamp to the fuel tube connector.
    4. Engage the 2 claws to install the No. 2 fuel pipe clamp.
  38. CONNECT WATER BY-PASS HOSE ASSEMBLY 
    1. w/ Heater Water Pump
      1. Align the protrusion of the water by-pass hose assembly connector with the cutout in the heater water pump assembly and securely insert the water by-pass hose assembly connector to the stopper of the pipe.
        GTY878540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protrusion
        *b Cutout
      2. Push in the retainer.
        GTY851772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push in
        Push
      3. Check that the heater water pump assembly and water by-pass hose assembly connector are securely connected by pulling on them.
    2. w/o Heater Water Pump
      1. Align the protrusion of the water by-pass hose assembly connector with the cutout in the water hose sub-assembly and securely insert the water by-pass hose assembly connector to the stopper of the pipe.
        GTY878540Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Protrusion
        *b Cutout
      2. Push in the retainer.
        GTY855290Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Retainer
        Push in
        Push
      3. Check that the water hose sub-assembly and water by-pass hose assembly connector are securely connected by pulling on them.
  39. CONNECT INLET HEATER WATER HOSE B 
    1. Connect the inlet heater water hose B to the water outlet and slide the clip to secure it.
    2. Engage the 2 clamps.
  40. CONNECT RADIATOR HOSE SUB-ASSEMBLY 
    1. Connect the radiator hose sub-assembly to the water outlet and slide the clip to secure it.
    2. Connect the No. 4 water by-pass hose to the radiator hose sub-assembly and slide the clip to secure it.
    3. Install the radiator hose sub-assembly to the engine assembly with the 2 bolts.

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

    4. Engage the clamp.
  41. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.
  42. CONNECT CONNECTOR TO CHECK VALVE HOSE 
    1. Connect the connector to check valve hose to the brake booster assembly and slide the clip to secure it.
  43. CONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Connect the No. 1 fuel vapor feed hose to the purge valve (purge VSV) and slide the clip to secure it.
  44. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.
    2. Connect the transmission control cable assembly to the transmission control shaft lever as shown in the illustration.
      GTY895832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Correct
      *b Incorrect
      NOTE:

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

  45. INSTALL BATTERY CLAMP SUB-ASSEMBLY 
    1. Install the battery clamp sub-assembly with the 3 bolts.

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

    2. Engage the 5 clamps to the battery clamp sub-assembly.
  46. INSTALL BATTERY 

    Refer to PROCEDURE - Step 1

  47. CONNECT ENGINE WIRE 
    1. Connect the engine wire to the negative (-) battery terminal with the nut.

      Torque: 7.6 N.m (77 kgf/cm, 67 in.lbf) 

  48. CONNECT ENGINE ROOM MAIN WIRE 
    1. Connect the engine wire with engine room main wire to the positive (+) battery terminal with the nut.

      Torque: 7.6 N.m (77 kgf/cm, 67 in.lbf) 

  49. INSTALL ECM 

    Refer to PROCEDURE - Step 3

  50. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 
    1. Install the air cleaner assembly with air cleaner hose to the throttle body with motor assembly.
      NOTE:

      Align the cutout of the air cleaner hose assembly with the protrusion of the throttle body with motor assembly.

      GTY930579Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Cutout
      *c Hose Clamp End
      *d 2.0 mm (0.0787 in.)
      *e Paint Mark
    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.

    3. Insert the 3 pins of the air cleaner assembly into the 3 air cleaner supports as shown in the illustration.
      GTY927583Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Air Cleaner Support
      NOTE:
      • Insert the 3 pins of the air cleaner assembly into the 3 air cleaner supports at the same time.
      • Check that the pins are securely inserted into air cleaner supports.
    4. Engage the vacuum hose to the air cleaner hose.
    5. Engage the 2 wire harness clamps.
    6. Connect the mass air flow meter sub-assembly connector.
    7. Connect the No. 2 ventilation hose to the air cleaner hose and slide the clip to secure it.
      NOTE:

      Make sure that the condition of the clip is as shown in the illustration.

      GTY905808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Fuel Vapor Feed Hose
      *2 No. 2 Ventilation Hose
      *3 Vacuum Hose Bracket
      *a Top
      *b Paint Mark
      *c Rear of Vehicle
      *d 180° (Claw of Clip Location)
    8. Engage the 2 clamps to connect the No. 1 fuel vapor feed hose to the air cleaner hose.
    9. Install the vacuum hose bracket to the air cleaner hose.
  51. INSTALL INLET AIR CLEANER ASSEMBLY 
    1. Install the inlet air cleaner assembly with the 2 bolts in the order shown in the illustration.

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

      Fig 2: Inlet Air Cleaner Assembly Bolts Tightening Sequence
      GTY861384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Engage the 4 clips in the order shown in the illustration to install the V-bank cover sub-assembly.
      NOTE:
      • Securely engage the clips.
      • If the clips are forcibly engaged or struck with an object, they may be damaged.
      Fig 3: V-Bank Cover Sub-Assembly Clip Engaging Sequence
      GTY855794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSPECT VACUUM HOSES 
    1. Inspect the vacuum hoses.
      GTY885413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

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

    Refer to INITIALIZATION [12/2019 - 09/2020]

  55. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 5

  56. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 2

  57. ADD AUTOMATIC TRANSAXLE FLUID (for 2WD) 

    Refer to ADJUSTMENT [12/2019 - 10/2022]

  58. ADD AUTOMATIC TRANSAXLE FLUID (for AWD) 

    Refer to ADJUSTMENT [12/2019 - 10/2022]

  59. ADD TRANSFER OIL (for AWD) 

    Refer to PROCEDURE - Step 2

  60. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  61. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  62. INSPECT SHIFT LEVER POSITION (for 2WD) 

    Refer to PROCEDURE - Step 2

  63. INSPECT SHIFT LEVER POSITION (for AWD) 

    Refer to PROCEDURE - Step 2

  64. ADJUST SHIFT LEVER POSITION (for 2WD) 

    Refer to PROCEDURE - Step 5

  65. ADJUST SHIFT LEVER POSITION (for AWD) 

    Refer to PROCEDURE - Step 5

  66. INSPECT FOR ENGINE OIL LEAK 

    Refer to PROCEDURE - Step 6

  67. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  68. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 5

  69. INSPECT FOR FUEL LEAK 

    Refer to ON-VEHICLE INSPECTION [12/2019 - 10/2022]

  70. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 6

  71. CHECK ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1

  72. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK 

    Refer to PROCEDURE - Step 2

  73. INSTALL FRONT BUMPER COVER 

    Refer to INSTALLATION [12/2019 - 09/2020]

  74. 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) 

  75. 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) 

  76. INSTALL FRONT FLOOR COVER RH 
    1. Install the front floor cover RH with the 5 bolts, 3 screws and 3 clips.

      Bolt 

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

  77. INSTALL FRONT FLOOR COVER LH 
    1. Install the front floor cover LH with the 4 bolts, 5 screws and 3 clips.

      Bolt 

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

  78. INSTALL REAR ENGINE UNDER COVER RH 
    1. Install the rear engine under cover RH with the bolt, screw and 3 clips.

      Bolt 

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

  79. INSTALL REAR ENGINE UNDER COVER LH 
    1. Install the rear engine under cover LH with the bolt, screw and 3 clips.

      Bolt 

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

  80. 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) 

  81. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 
    1. Install the front wheel opening extension pad LH with the 4 screws.
  82. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 
    1. Install the front wheel opening extension pad RH with the 4 screws.
  83. INSTALL FRONT WHEELS 

    Refer to PROCEDURE - Step 1

  84. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  85. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [12/2019 - 09/2020]

  86. PERFORM INITIALIZATION 

    Refer to PROCEDURE - Step 6

  87. INSPECT IGNITION TIMING 

    See step  9

  88. INSPECT ENGINE IDLE SPEED 

    See step  10

  89. INSPECT CO/HC 

    See step  12

  90. CHECK FOR SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [12/2019 - 11/2023]

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