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Home >> Toyota Truck >> 2005 >> Highlander 2WD V6-3.3L (3MZ-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Partial Engine Assembly Replacement >> Part 4

Part 4

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PARTIAL ENGINE ASSEMBLY
REPLACEMENT
121. INSTALL STARTER ASSEMBLY
122. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
123. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (2WD TYPE)
124. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (4WD TYPE)
125. INSTALL FRONT FRAME ASSEMBLY





a. Install the engine mounting insulator RH and LH with the 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)





b. Install the engine mounting insulator FR with the nut.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)





c. Install the engine mounting insulator RR with the 2 bolts.
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
126. INSTALL POWER STEERING LINK ASSEMBLY
127. INSTALL STABILIZER BAR FRONT





128. INSTALL VANE PUMP ASSEMBLY
a. Install the vane pump with the 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

HINT: After adjusting the V-ribbed belt, tighten bolt A.

129. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY





a. Install a new gasket and the exhaust manifold RH. Uniformly tighten the 6 nuts in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Retighten nuts 1 and 2 shown in the illustration.





c. Install the insulator with the 3 bolts, as shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
d. Connect the A/F sensor connector.
130. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE





a. Set the engine assembly with transaxle on the engine lifter.
b. Install the engine assembly to the vehicle.
c. Install the frame side rail plate RH and LH with the 6 bolts and 2 nuts.
Torque:
85 Nm (867 kgf-cm, 63 ft. lbs.) for bolt A
32 Nm (326 kgf-cm, 24 ft. lbs.) for bolt B and nut C





d. Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.
Torque:
85 Nm (867 kgf-cm, 63 ft. lbs.) for bolt A
32 Nm (326 kgf-cm, 24 ft. lbs.) for bolt B and nut C
131. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY





a. Align the matchmarks on the intermediate shaft and the control valve shaft, and install the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)





b. Tighten the sliding yoke bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
132. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT





a. Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
b. Using kerosene or gasoline, clean the bolts thoroughly.
c. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent





d. Install the 6 torque converter set bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft. lbs.)

NOTICE: First tighten the green colored bolt and then tighten the 5 bolts.

e. Install the flywheel housing under cover with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 70 inch lbs.)





133. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
a. Install the drive shaft to the steering knuckle.
b. Install the suspension lower arm with the bolt and 2 nuts.
Torque: 127 Nm (1,295 kgf-cm, 94 ft. lbs.)
134. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

HINT: Use the same procedures described for the LH side.

135. INSTALL TIE ROD END SUB-ASSEMBLY LH
a. Connect the tie rod end to the steering knuckle and install a new castle nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

NOTICE:
^ Prevent any lubricant from contacting the thread and the taper portions.
^ After tightening the castle nut, tighten it to the additional direction within 60° to put into a cotter pin.

b. Insert a new cotter pin.
136. INSTALL TIE ROD END SUB-ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

137. INSTALL SPEED SENSOR FRONT LH
138. INSTALL SPEED SENSOR FRONT RH





139. INSTALL FRONT AXLE HUB LH NUT
a. Using a 30 mm socket wrench, install a new hub nut.
Torque: 294 Nm (2,998 kgf-cm, 217 ft. lbs.)
b. Using a chisel and hammer, tap the front axle hub LH nut.
140. INSTALL FRONT AXLE HUB RH NUT

HINT: Use the same procedures described for the LH side.

141. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
a. Using a 6 mm socket hexagon wrench, hold the ball stud and install the nut.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
142. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

143. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1
144. CONNECT EXHAUST PIPE ASSEMBLY FRONT
145. CONNECT EXHAUST PIPE SUB-ASSEMBLY FRONT NO.3
146. INSTALL PROPELLER SHAFT (4WD TYPE)
147. CONNECT ENGINE WIRE
148. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
149. CONNECT STEERING GEAR OUTLET RETURN TUBE
150. CONNECT OIL RESERVOIR TO PUMP HOSE NO.1
151. CONNECT OIL COOLER OUTLET TUBE NO.1
152. CONNECT OIL COOLER INLET TUBE NO.1
153. CONNECT RADIATOR HOSE OUTLET
154. CONNECT RADIATOR HOSE INLET
155. CONNECT HEATER OUTLET WATER HOSE
156. CONNECT HEATER INLET WATER HOSE





157. CONNECT FUEL PIPE SUB-ASSEMBLY NO.1
a. Push in the fuel tube connector to the fuel pipe until connector makes a "click" sound.

NOTICE:
^ Check for damage or contamination on the connected part of the pipe.
^ After having finished the connection, check if the pipe and the connector are securely connected by trying to pull them apart.

b. Install the fuel pipe clamp.
158. CONNECT UNION TO CHECK VALVE HOSE
159. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY





160. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the compressor with the 3 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
b. Install the adjusting bar bracket with the bolt and nut.
Torque:
25 Nm (255 kgf-cm, 18 ft. lbs.) for bolt
26 Nm (265 kgf-cm, 19 ft. lbs.) for nut





161. INSTALL ENGINE MOUNTING STAY NO.2 RH
a. Install the mounting stay and mounting bracket with the bolt.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)





162. INSTALL ENGINE MOVING CONTROL ROD
a. Install the control rod and bracket with the 4 bolts.
Torque:
64 Nm (653 kgf-cm, 47 ft. lbs.) for bolt A
23 Nm (235 kgf-cm, 17 ft. lbs.) for bolt B





163. INSTALL GENERATOR BELT ADJUSTING BAR
a. Install the adjusting bar with the 2 bolts and 2 nuts.
Torque:
43 Nm (438 kgf-cm, 32 ft. lbs.) for nut A
18 Nm (184 kgf-cm, 13 ft. lbs.) for bolt B
8.0 Nm (82 kgf-cm, 71 inch lbs.) for bolt C
164. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
165. INSTALL GENERATOR ASSEMBLY
166. INSTALL VANE PUMP V BELT
167. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
168. INSPECT DRIVE BELT TENSION
169. INSTALL AIR CLEANER CASE
170. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
171. INSTALL AIR CLEANER CAP SUB-ASSEMBLY





172. CONNECT VACUUM HOSES
173. INSTALL BATTERY





174. INSTALL V-BANK COVER SUB-ASSEMBLY
a. Fit the 2 retainers and install the V-bank cover.
b. Using a socket hexagon wrench 5, tighten the 3 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
175. INSTALL FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
176. INSTALL COWL PANEL SUB-ASSEMBLY
177. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
178. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
179. INSTALL FR WIPER ARM LH
180. INSTALL FR WIPER ARM RH
181. INSTALL FRONT WHEELS
182. ADD TRANSFER OIL (4WD TYPE)
183. INSPECT TRANSFER OIL (4WD TYPE)
184. ADD AUTOMATIC TRANSAXLE FLUID
185. ADD ENGINE OIL
186. ADD ENGINE COOLANT
187. ADD POWER STEERING FLUID
188. BLEED POWER STEERING FLUID
189. INSPECT AUTOMATIC TRANSAXLE FLUID
190. CHECK FOR ENGINE OIL LEAKS
191. CHECK FOR ENGINE COOLANT LEAKS
192. CHECK POWER STEERING FLUID LEAKAGE
193. INSPECT FOR FUEL LEAKS
194. CHECK FOR EXHAUST GAS LEAKS
195. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
196. INSPECT IGNITION TIMING
197. INSPECT ENGINE IDLE SPEED
198. INSPECT CO/HC
199. CHECK ABS SPEED SENSOR SIGNAL

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