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Home >> Toyota Truck >> 2011 >> Highlander 4WD V6-3.5L (2GR-FXE) Hybrid >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine Assembly >> Installation

Installation





2GR-FXE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

CAUTION:
As the engine assembly with transaxle is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

1. INSTALL ENGINE MOUNTING INSULATOR LH

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

(a) Install the engine mounting insulator LH with the nut.

Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

(b) Install the dynamic damper with the bolt.

Torque : 14 Nm (138 kgf-cm, 10 ft-lbf)

2. INSTALL ENGINE MOUNTING INSULATOR RH

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

(a) Install the engine mounting insulator RH with the 3 nuts.

Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)

(b) Install the 2 hole plugs.

3. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY

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

(a) Install the rear engine mounting insulator assembly with the 2 nuts.

Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

4. INSTALL FRONT ENGINE MOUNTING INSULATOR

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

(a) Install the front engine mounting insulator with the 3 nuts.

Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

(b) Install the hole plug.

5. INSTALL ENGINE HANGER

(a) Install a No. 1 and No. 2 engine hanger with 4 bolts.





Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)

Text in Illustration





HINT






6. REMOVE ENGINE FROM ENGINE STAND

(a) Attach an engine sling device and hang the engine with a chain block.

(b) Lift the engine and remove it from the engine stand.

NOTICE:
* With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
* Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

7. FIX ENGINE ASSEMBLY

(a) Using wooden blocks or plate lift attachments, set the engine on a flat surface.

NOTICE:
* Place wooden blocks or plate lift attachments so that the engine is level.
* Never install attachments to the oil pan of the engine assembly or transaxle as doing so may deform the oil pan.
* Perform this step while supporting the engine assembly using a sling device and chain block.

8. INSTALL FLYWHEEL SUB-ASSEMBLY Installation

9. INSTALL TRANSMISSION INPUT DAMPER ASSEMBLY Installation

10. INSTALL RADIATOR PIPE CLAMP

(a) Install the radiator pipe clamp with the bolt.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

11. INSTALL HYBRID VEHICLE TRANSAXLE ASSEMBLY

Installation

12. INSTALL FRONT FRAME ASSEMBLY

(a) Set the frame on an engine lifter as shown in the illustration.





NOTICE:
Place wooden blocks or plate lift attachments so that the front frame is level.

(b) Slowly lower the engine with hybrid vehicle transaxle assembly into the engine compartment.

NOTICE:
* With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
* Never install attachments to the oil pan of the engine assembly or transaxle as doing so may deform the oil pan.
* Do not damage any engine or transaxle components.

HINT
Lower the engine with hybrid transaxle assembly while keeping it level.

(c) Install the engine mounting insulator RH with the nut.

Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

(d) Install the engine mounting insulator LH with the 3 nuts.

Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)

(e) Install the 2 hole plugs.

(f) Install the front engine mounting insulator with the bolt.

Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)

(g) Install the rear engine mounting insulator assembly with the 2 bolts.

Torque : 75 Nm (765 kgf-cm, 55 ft-lbf)

(h) Connect the engine wire with the 2 clamps.

(i) Remove the 4 bolts and 2 engine hangers.

(j) Install the wire harness bracket with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(k) Connect the wire harness.

13. INSTALL EXHAUST MANIFOLD TO HEAD GASKET LH Installation

14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation

15. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation

16. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE Installation

17. INSTALL NO. 2 MANIFOLD STAY Installation

18. INSTALL EXHAUST MANIFOLD TO HEAD GASKET Installation

19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

20. INSTALL NO. 1 EGR PIPE Installation

21. INSTALL MANIFOLD STAY Installation

22. INSTALL EGR COOLER ASSEMBLY Installation

23. INSTALL NO. 2 EGR PIPE Installation

24. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Installation

25. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Install the engine assembly with transaxle to the vehicle.

NOTICE:
* Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.
* Make sure that the engine is clear of all wiring and hoses.
* While raising the engine into the vehicle, do not allow it to contact the vehicle.

(b) Install the front suspension member rear brace RH and LH with the 6 bolts and 2 nuts.





for bolt A - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

for nut B - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

for bolt C - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

(c) Install the frame side rail plate RH and LH with the 6 bolts and 2 nuts.

for bolt D - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

for nut E - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

for bolt F - Torque : 32 Nm (326 kgf-cm, 24 ft-lbf)

26. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

27. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET

(a) Install the No. 1 exhaust pipe support bracket with the 2 nuts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

28. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING Reassembly

29. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

30. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

31. INSTALL FRONT LOWER SUSPENSION ARM LH Installation

32. INSTALL FRONT LOWER SUSPENSION ARM RH

HINT
Perform the same procedure as for the LH side.

33. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

34. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

35. CONNECT TIE ROD ASSEMBLY LH Installation

36. CONNECT TIE ROD ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

37. INSTALL FRONT SPEED SENSOR LH Installation

38. INSTALL FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

39. INSTALL FRONT AXLE SHAFT NUT LH Installation

40. INSTALL FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

41. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

42. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

43. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY Installation

44. CONNECT FUEL MAIN TUBE

Service Precautions

45. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation

46. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation

47. CONNECT ENGINE WIRE

(a) Connect the ECM connector and attach the wire harness clamp.

NOTICE:
* When connecting the connector, make sure that dirt, water or other foreign matter does not become stuck between the connector and other parts.
* Make sure that the lever is securely locked.

(b) Connect the ground wire with the 2 bolts.

Torque : 8.5 Nm (85 kgf-cm, 75 in-lbf)

(c) Install the ground wire with the bolt.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

(d) Connect the engine wire with the bolt.

Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

(e) Attach the 6 clamps.

(f) Connect the 3 wire connectors.

(g) Install the relay block cover to the relay block.

48. INSTALL ENGINE MOVING CONTROL ROD

(a) Install the engine moving control rod with the 4 bolts.

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

49. INSTALL NO. 2 ENGINE MOUNTING STAY RH Installation

50. INSTALL RESERVOIR BRACKET Installation

51. CONNECT BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY Installation

52. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Installation

53. CONNECT PURGE LINE HOSE

(a) Connect the purge line hose.

54. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose.





Text in Illustration





HINT
Make sure the direction of the hose clamp is as shown in the illustration.

55. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose.





Text in Illustration





HINT
Make sure the direction of the hose clamp is as shown in the illustration.

56. INSTALL NO. 1 RADIATOR HOSE

(a) Install the No. 1 radiator hose.





Text in Illustration





HINT
Make sure the direction of the hose clamp is as shown in the illustration.

(b) Connect the No. 1 radiator hose to the radiator pipe clamp.

57. INSTALL NO. 2 RADIATOR HOSE

(a) Install the No. 2 radiator hose.





Text in Illustration





HINT
Make sure the direction of the hose clamp is as shown in the illustration.

58. CONNECT NO. 3 MOTOR COOLING HOSE

(a) Connect the No. 3 motor cooling hose.

59. CONNECT NO. 1 MOTOR COOLING HOSE

(a) Connect the No. 1 motor cooling hose.

60. INSTALL INVERTER TRAY BRACKET SUB-ASSEMBLY

(a) Install the inverter tray bracket sub-assembly with the 5 bolts.

Torque : 17 Nm (173 kgf-cm, 12 ft-lbf)

(b) Attach the clamp and connect the water by-pass hose.

61. INSTALL INVERTER WITH CONVERTER ASSEMBLY Installation

62. INSTALL NO. 4 INVERTER BRACKET Installation

63. CONNECT NO. 2 ENGINE ROOM WIRE Installation

64. CONNECT WATER HOSE Installation

65. CONNECT MG ECU CONNECTOR Installation

66. INSTALL NO. 3 ENGINE ROOM RELAY BLOCK Installation

67. REMOVE INVERTER TERMINAL COVER Installation

68. CONNECT NO. 3 WIRE FRAME Installation

69. CONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR Installation

70. CONNECT NO. 4 ENGINE WIRE Installation

71. CHECK HIGH VOLTAGE CABLE CONNECTION Installation

72. INSTALL INVERTER TERMINAL COVER Installation

73. INSTALL NO. 1 INVERTER RESERVE TANK BRACKET Installation

74. INSTALL INVERTER RESERVE TANK ASSEMBLY Installation

75. INSTALL NO. 2 RADIATOR ASSEMBLY Installation

76. INSTALL UPPER RADIATOR SUPPORT SUB-ASSEMBLY Installation

77. INSTALL HOOD LOCK ASSEMBLY (w/ Engine Hood Courtesy Switch) Installation

78. INSTALL HOOD LOCK ASSEMBLY (w/o Engine Hood Courtesy Switch) Installation

79. INSTALL HIGH PITCHED HORN ASSEMBLY Installation

80. INSTALL LOW PITCHED HORN ASSEMBLY Installation

81. INSTALL FRONT BUMPER COVER Installation

82. INSTALL RADIATOR GRILLE Installation

83. CONNECT NO. 2 RADIATOR HOSE Installation

84. CONNECT NO. 1 RADIATOR HOSE Installation

85. INSTALL RADIATOR RESERVOIR Installation

86. INSTALL NO. 3 INVERTER BRACKET Installation

87. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY Installation

88. INSTALL AIR CLEANER ASSEMBLY WITH HOSE Installation

89. INSTALL NO. 1 AIR CLEANER INLET Installation

90. INSTALL NO. 2 AIR CLEANER INLET Installation

91. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY Installation

92. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Attach the 4 retainers and install the V-bank cover sub-assembly.

93. INSTALL SERVICE PLUG GRIP Installation

94. INSTALL RECLINING HINGE COVER LH Installation

95. INSTALL REAR DOOR SCUFF PLATE LH Installation

96. ADD ENGINE OIL Replacement

97. ADD HYBRID TRANSAXLE FLUID Q211 Hybrid Transaxle

98. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

99. INSTALL BATTERY SERVICE HOLE COVER ASSEMBLY Installation

100. INSTALL DECK BOARD ASSEMBLY Installation

101. ADD ENGINE COOLANT Coolant (for Engine)

102. ADD COOLANT (for Inverter) Coolant (for Inverter)

103. INSPECT ENGINE OIL LEVEL Testing and Inspection

104. INSPECT COOLANT LEVEL IN RESERVOIR (for Engine) Cooling System

105. CHARGE WITH REFRIGERANT Service and Repair

106. INSPECT FOR FUEL LEAK Fuel System

107. INSPECT FOR ENGINE COOLANT LEAK Cooling System

108. INSPECT FOR COOLANT LEAK (for Inverter) Testing and Inspection

109. INSPECT AND ADJUST HYBRID TRANSAXLE FLUID P313 Hybrid Transaxle

110. INSPECT FOR ENGINE OIL LEAK Replacement

111. INSPECT FOR REFRIGERANT LEAK Service and Repair

112. INSPECT FOR EXHAUST GAS LEAK Installation

113. INSTALL FRONT FENDER APRON SEAL RH Installation

114. CONNECT FRONT FENDER LINER RH Installation

115. CONNECT FRONT FENDER LINER LH

HINT
Perform the same procedure as for the RH side.

116. INSTALL FRONT FLOOR COVER LH Installation

117. INSTALL NO. 2 ENGINE UNDER COVER

(a) Install the No. 2 engine under cover with the 4 bolts and clip.

118. INSTALL NO. 1 ENGINE UNDER COVER Coolant (for Engine)

119. INSTALL FRONT WHEEL

120. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

121. INSPECT SHIFT LEVER POSITION Initial Inspection and Diagnostic Overview

122. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Front Wheel Alignment

123. INSPECT IGNITION TIMING Engine

124. INSPECT ENGINE IDLE SPEED Engine

125. INSPECT CO/HC Engine

126. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

127. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

128. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

129. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

130. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

131. CHECK FOR SPEED SENSOR SIGNAL

Test Mode Procedure

132. INSTALL COOL AIR INTAKE DUCT SEAL Installation
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