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Home >> Toyota Truck >> 2012 >> Highlander 2WD L4-2.7L (1AR-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine >> Installation

Installation





1AR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL ENGINE HANGERS Removal

2. REMOVE ENGINE STAND

3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Installation

4. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Installation

5. INSTALL ENGINE MOUNTING BRACKET RH

(a) Install the engine mounting bracket RH with the 3 bolts.





Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

6. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR

(a) Temporarily install the front engine mounting insulator with the nut.





7. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH

(a) Temporarily install the engine mounting insulator LH with the nut.





8. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH

(a) Temporarily install the engine mounting insulator RH with the nut.





9. INSTALL FRONT FRAME ASSEMBLY

(a) Install the engine assembly with transaxle with the 9 nuts.





A - Torque : 52 Nm (531 kgf-cm, 39 ft-lbf)

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

(b) Tighten the 3 nuts.





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

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

(c) Install the 5 hole plugs.





10. INSTALL DRIVE SHAFT BEARING BRACKET

(a) Install the drive shaft bearing bracket with the 3 bolts.





Torque : 64 Nm (650 kgf-cm, 47 ft-lbf)

11. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH Reassembly

12. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

13. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

14. INSTALL STARTER ASSEMBLY Installation

15. INSTALL COMPRESSOR AND MAGNETIC CLUTCH Installation

16. INSTALL GENERATOR ASSEMBLY Installation

17. INSTALL V-RIBBED BELT Installation

18. INSTALL ENGINE WIRE

19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle on the engine lifter.

(b) Remove engine hangers Removal.

(c) Install the engine assembly to the vehicle.

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





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

Bolt B - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

Nut C - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

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





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

Bolt B - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

Nut C - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

20. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

(a) Using SST, hold the crankshaft pulley.





SST : 09213-54015

SST : 09330-00021

SST : 91551-80650

(b) Apply a few drops of adhesive to the 2 or 3 end threads of the 6 drive plate and torque converter clutch setting bolts.





Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(c) Install the 6 drive plate and torque converter clutch setting bolts.





Torque : 41 Nm (418 kgf-cm, 30 ft-lbf)

NOTICE:
Install the black colored bolt first, and then the 5 silver colored bolts.

21. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover.





22. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY Installation

23. INSTALL FRONT AXLE ASSEMBLY LH Installation

24. INSTALL FRONT AXLE ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

25. INSTALL NO. 1 FRONT LOWER SUSPENSION ARM LH Installation

26. INSTALL NO. 1 FRONT LOWER SUSPENSION ARM RH

HINT
Use the same procedure described for the LH side.

27. CONNECT TIE ROD ASSEMBLY LH Installation

28. CONNECT TIE ROD ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

29. INSTALL FRONT SPEED SENSOR LH Installation

30. INSTALL FRONT SPEED SENSOR RH

HINT
Use the same procedure described for the LH side.

31. INSTALL FRONT AXLE HUB NUT LH Installation

32. INSTALL FRONT AXLE HUB NUT RH

HINT
Use the same procedure described for the LH side.

33. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

34. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Use the same procedure described for the LH side.

35. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

36. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation

37. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation

38. CONNECT UNION TO CHECK VALVE HOSE

(a) Connect the 2 union to check valve hoses.





39. INSTALL ENGINE MOVING CONTROL ROD

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





(b) Temporarily install the No. 2 engine mounting stay with the 2 bolts.





(c) Tighten the 6 bolts.

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

40. CONNECT ENGINE WIRE

(a) Connect the 4 ECM connectors, 2 junction block connectors and clamp.





(b) Install the engine wire with the 2 nuts and clamp.





Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(c) Install the ground cable with the bolt.





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

(d) Install the ground cable with the 2 bolts.





A - Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

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

(e) Install the positive (+) cable with the nut and 2 clamps.





Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

(f) Install the ground cable with the bolt.





Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(g) Connect the engine wire clamp.

(h) Connect the engine wire clamp.





(i) Connect the engine wire to the engine room relay block.





(j) Install the nut, and connect the engine wire connector.





Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(k) Install the No. 1 relay block cover.





41. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Install a new clip to the control cable bracket.

(b) Install the control cable to the control cable bracket.





NOTICE:
* Make sure that the A claws on the clip are securely fit into the bracket holes.
* Make sure that the cable is securely installed inside the B claws of the clip.

(c) Connect the transmission control cable to the control shaft lever with the nut.





Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)

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

42. CONNECT OUTLET OIL COOLER HOSE

(a) Connect the outlet oil cooler hose.





43. CONNECT INLET OIL COOLER HOSE

(a) Connect the inlet oil cooler hose.

44. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Push in the fuel tube connector to the fuel pipe until the fuel tube makes a "click" sound.





NOTICE:
* Check for damage or dirt and foreign objects on the connected part of the pipe.
* Check if the pipe and the connector are securely connected by trying to pull them apart.

(b) Install the No. 1 fuel pipe clamp.





45. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose.





46. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose.





47. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose.





48. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose.





49. INSTALL RESERVOIR BRACKET

(a) Install the reservoir bracket with the 2 bolts.





Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

50. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

(a) Install the brake master cylinder reservoir assembly with the bolt.





Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

(b) Connect the level warning switch connector.

51. INSTALL NO. 1 INLET AIR CLEANER

(a) Install the No. 1 inlet air cleaner with the bolt.





Torque : 7.0 Nm (72 kgf-cm, 62 in-lbf)

52. INSTALL AIR CLEANER BRACKET

(a) Install the air cleaner bracket with the 2 bolts.





Torque : 13 Nm (127 kgf-cm, 9 ft-lbf)

53. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Install the air cleaner case sub-assembly with the 3 bolts and 2 clamps.





Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

54. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

(a) Install the air cleaner filter element sub-assembly.

55. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

56. INSTALL NO. 2 INLET AIR CLEANER

(a) Install the No. 2 inlet air cleaner with the 2 bolts.





Torque : 7.0 Nm (72 kgf-cm, 62 in-lbf)

(b) Connect the 2 clamps and vacuum hose.

57. INSTALL BATTERY

(a) Install the battery tray and battery.

(b) Install the battery clamp with the bolt and nut.





Torque : 5.4 Nm (55 kgf-cm, 47 in-lbf)

(c) Install the positive (+) battery terminal with the nut.

Torque : 6.4 Nm (65 kgf-cm, 57 in-lbf)

58. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

59. INSTALL EJECTOR TUBE Installation

60. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

61. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

62. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

63. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

64. INSTALL FRONT WHEELS

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

65. 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.

66. ADD ENGINE OIL Replacement

67. ADD ENGINE COOLANT Service and Repair

68. ADD AUTOMATIC TRANSAXLE FLUID

HINT
Procedures.

69. CHARGE WITH REFRIGERANT Service and Repair

70. INSPECT FOR FUEL LEAK Fuel System

71. INSPECT FOR OIL LEAK

72. INSPECT FOR COOLANT LEAK Testing and Inspection

73. INSPECT FOR EXHAUST GAS LEAK

74. INSPECT FOR REFRIGERANT LEAK Service and Repair

75. INSPECT AND ADJUST SHIFT LEVER POSITION

HINT
Adjustments.

76. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

HINT
Front Wheel Alignment.

77. INSPECT IGNITION TIMING Engine

78. INSPECT ENGINE IDLE SPEED Engine

79. INSPECT CO/HC Engine

80. INSTALL FRONT FENDER APRON SEAL RH

(a) Install the front fender apron seal RH with the 2 bolts and clip.





81. INSTALL FRONT FENDER APRON SEAL LH

(a) Install the front fender apron seal LH with the 2 bolts and clip.





82. INSTALL FRONT FENDER LINER LH Installation

83. INSTALL FRONT FENDER LINER RH Installation

84. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY LH Installation

85. INSTALL FRONT FENDER MOULDING SUB-ASSEMBLY RH Installation

86. INSTALL FLOOR UNDER COVER LH

87. INSTALL NO. 2 ENGINE UNDER COVER

88. INSTALL NO. 1 ENGINE UNDER COVER

89. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

(a) Fit the 3 retainers and install the No. 1 engine cover sub-assembly.





90. INSTALL COOL AIR INTAKE DUCT SEAL

(a) Install the cool air intake duct seal with the 11 clips.





91. CHECK ABS SPEED SENSOR SIGNAL

HINT
Test Mode Procedure.

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