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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 24 (Engine Mechanical System (A25A-FXS) - Service Information (3 Of 3)) >> Engine Unit >> Installation [12/2019 - 10/2021] >> Procedure

Installation [12/2019 - 10/2021]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the No. 3 exhaust manifold heat insulator to the cylinder block sub-assembly with the bolt.

      Torque: 16 N.m (163 kgf/cm, 12 ft.lbf) 

  2. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Apply a light coat of engine oil to a new O-ring.
    2. Install the O-ring to the engine oil level dipstick guide.
    3. Using an 8 mm socket wrench, install the engine oil level dipstick guide to the camshaft housing sub-assembly with the bolt.

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

    4. Install the engine oil level dipstick.
  3. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  4. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  5. INSTALL FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 3

  6. INSTALL PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  7. INSTALL NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 2

  8. INSTALL INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 3

  9. INSTALL NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 4

  10. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  11. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Using an 8 mm socket wrench, install the wire harness clamp bracket to the No. 1 ventilation case with the 2 bolts.

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

  12. INSTALL NO. 6 ENGINE WIRE 
    1. Install the No. 6 engine wire to the wire harness clamp bracket with the 2 nuts.

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

    2. Engage the 2 clamps.
    3. Connect the 4 connectors.
  13. INSTALL SENSOR WIRE 
    1. Using an 8 mm socket wrench, install the sensor wire to the water inlet with thermostat sub-assembly with the bolt.

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

    2. Engage the 3 clamps.
    3. Connect the 4 connectors.
  14. INSTALL NO. 7 WATER BY-PASS HOSE 
    1. Install the No. 7 water by-pass hose and slide the 2 clips to secure it.
  15. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 1

  16. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  17. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 3

  18. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. for EGR Valve Bracket Connection Type:
      1. Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.
        GTY742679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 17 mm Union Nut Wrench
        *b Torque Wrench Fulcrum Length

        Specified tightening torque 

        Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

        NOTE:

        Do not adjust the torque in the loosening direction.

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [12/2019 - 11/2023]

        • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N.m (306 kgf/cm, 22 ft.lbf)
      2. Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

        Specified tightening torque 

        Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

        NOTE:

        Do not adjust the torque in the loosening direction.

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [12/2019 - 11/2023]

        • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N.m (306 kgf/cm, 22 ft.lbf)
    2. for Cylinder Head Cover Sub-assembly Connection Type:
      1. Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.

        Specified tightening torque 

        Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

        NOTE:

        Do not adjust the torque in the loosening direction.

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [12/2019 - 11/2023]

        • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N.m (306 kgf/cm, 22 ft.lbf)
        GTY947610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a 17 mm Union Nut Wrench
        *b Torque Wrench Fulcrum Length
      2. Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

        Specified tightening torque 

        Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

        NOTE:

        Do not adjust the torque in the loosening direction.

        HINT: 

        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

          Refer to PRECAUTION [12/2019 - 11/2023]

        • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N.m (306 kgf/cm, 22 ft.lbf)
      3. Using an 8 mm socket wrench, install the bolt.

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

  19. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  20. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 3

  21. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 4

  22. INSTALL NO. 2 WATER BY-PASS PIPE 
    1. Install the bolt (A).
      GTY768411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

    2. Using an 8 mm socket wrench, install the No. 2 water by-pass pipe with the 2 bolts (B).

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

  23. INSTALL NO. 3 WATER BY-PASS PIPE 
    1. Install the No. 3 water by-pass pipe to the water outlet and slide the clip to secure it.
    2. Using an 8 mm socket wrench, connect the No. 3 water by-pass pipe to the intake manifold with the bolt.

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

  24. INSTALL EGR VALVE ASSEMBLY 
    1. Using an 8 mm socket wrench, install the EGR valve bracket with the bolt.

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

    2. for EGR Valve Bracket Connection Type:
      1. Align and fit the hole of the EGR valve bracket to the pin of the camshaft housing sub-assembly.
        GTY759336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Pin
        *b Hole
      2. Using the 8 mm socket wrench, install the EGR valve assembly with the EGR valve bracket to the camshaft housing sub-assembly with the bolt.

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

      3. Using the 8 mm socket wrench, connect the No. 1 fuel pipe sub-assembly to the EGR valve bracket with the bolt.

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

    3. for Cylinder Head Cover Sub-assembly Connection Type:
      1. Align and fit the hole of the EGR valve bracket to the pin of the camshaft housing sub-assembly.
        GTY948317Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Pin
        *b Hole
      2. Using the 8 mm socket wrench, install the EGR valve assembly with the EGR valve bracket to the camshaft housing sub-assembly with the bolt.

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

    4. Connect the No. 8 water by-pass hose to the EGR valve assembly and slide the clip to secure it.
  25. INSTALL NO. 4 WATER BY-PASS HOSE 
    1. Install the No. 4 water by-pass hose to the EGR valve assembly and slide the clip to secure it.
  26. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  27. INSTALL EGR COOLER ASSEMBLY 
    1. Install the EGR cooler assembly, a new EGR cooler gasket and a new EGR valve gasket with the 5 bolts.

      Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

    2. Connect the No. 3 water by-pass hose to the EGR cooler assembly and slide the clip to secure it.
    3. Connect the No. 4 water by-pass hose to the EGR cooler assembly and slide the clip to secure it.
  28. INSTALL THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 1 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 1 [09/2020 - ]

  29. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 2 [09/2020 - ]

  30. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 2

  31. INSTALL MANIFOLD STAY 

    Refer to PROCEDURE - Step 3

  32. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 5 bolts.

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

  33. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY) 
    1. Install the water hose clamp bracket with the 2 bolts as shown in the illustration.

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

      GTY840816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

    2. Connect the flow shutting valve (water by-pass hose assembly) to the water by-pass outlet and slide the clip to secure it.
      GTY854742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark
      *b 45° (Claw of Clip Location)
      NOTE:
      • Make sure to slide the flow shutting valve (water by-pass hose assembly) until it contacts the hose stopper of the water by-pass outlet.
      • Make sure that the claws of the clip are within the location shown in the illustration.
    3. Install the flow shutting valve (water by-pass hose assembly) with the bolt.

      Torque: 19 N.m (194 kgf/cm, 14 ft.lbf) 

  34. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. Install the No. 2 water by-pass pipe sub-assembly with the bolt.

      Torque: 19 N.m (194 kgf/cm, 14 ft.lbf) 

    2. Connect the No. 2 water by-pass pipe sub-assembly to the water by-pass outlet and slide the clip to secure it.
  35. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 
    1. Using an E8 "TORX" socket wrench, temporarily install the compressor with motor assembly with the 2 stud bolts.

      Torque: 4.0 N.m (41 kgf/cm, 35 in.lbf) 

    2. Install the compressor with motor assembly with the bolt and 2 nuts.
      Fig 1: Compressor With Motor Assembly Bolt And Nuts Tightening Sequence
      GTY769374Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Torque: 24.5 N.m (250 kgf/cm, 18 ft.lbf) 

      HINT: 

      Tighten the bolt and nuts in the order shown in the illustration.

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

      Torque: 63.7 N.m (650 kgf/cm, 47 ft.lbf) 

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