LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2009 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 4 (Engine Mechanical (1AR-FE)) >> Engine Assembly >> Removal

Engine Assembly: Removal

WARNING: This page is about a different variant/trim than selected.
  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM  (See REPLACEMENT )
  2. DISCHARGE FUEL SYSTEM PRESSURE 

    HINT:

    See FUEL SYSTEM .

  3. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  4. REMOVE FRONT WHEELS 
  5. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See INITIALIZATION ).
  6. REMOVE COOL AIR INTAKE DUCT SEAL 
    1. Remove the 11 clips and cool air intake duct seal.
  7. REMOVE NO. 1 ENGINE UNDER COVER 
  8. REMOVE NO. 2 ENGINE UNDER COVER 
  9. REMOVE FLOOR UNDER COVER LH 
  10. REMOVE FRONT FENDER MOULDING SUB-ASSEMBLY LH  (See REMOVAL )
  11. REMOVE FRONT FENDER MOULDING SUB-ASSEMBLY RH  (See ON-VEHICLE INSPECTION )
    Fig 1: Locating Cool Air Intake Duct Seal Clips
    G06112108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FRONT FENDER LINER LH  (See REMOVAL )
  13. REMOVE FRONT FENDER LINER RH  (See REMOVAL )
  14. REMOVE FRONT FENDER APRON SEAL LH 
    1. Remove the 2 bolts, clip and front fender apron seal LH.
    Fig 2: Locating Front Fender Apron Seal LH Bolts And Clip
    G06112109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE FRONT FENDER APRON SEAL RH 
    1. Remove the 2 bolts, clip and front fender apron seal RH.
  16. DRAIN ENGINE OIL  (See REPLACEMENT )
  17. DRAIN ENGINE COOLANT  (See COOLANT )
  18. DRAIN AUTOMATIC TRANSAXLE FLUID  (See COMPONENTS )
    Fig 3: Locating Front Fender Apron Seal RH Bolts And Clip
    G06112110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  20. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  21. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  22. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See REMOVAL )
  23. SEPARATE EJECTOR TUBE  (See REMOVAL )
  24. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY  (See REMOVAL )
  25. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Lift the rear of the No. 1 engine cover sub-assembly to detach the cover from the 2 pins, and then lift the front of the No. 1 engine cover sub-assembly to detach the cover from the pin and remove the No. 1 engine cover sub-assembly.
    NOTE: Attempting to disengage both front and rear clips at the same time may cause the No. 1 engine cover sub-assembly to break.
    Fig 4: Locating No. 1 Engine Cover
    G06030140Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE BATTERY 
    1. Remove the nut, and separate the positive (+) battery terminal.
    2. Loosen the nut, and remove the bolt and battery clamp.
    3. Remove the battery and battery tray.
    Fig 5: Locating Positive (+) Battery Terminal And Nut
    G06112112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE NO. 2 INLET AIR CLEANER 
    1. Disconnect the 2 clamps and vacuum hose.
    2. Remove the 2 bolts and No. 2 inlet air cleaner.
  28. REMOVE AIR CLEANER CAP SUB-ASSEMBLY  (See REMOVAL )
  29. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
    1. Remove the air cleaner filter element sub-assembly.
    Fig 6: Locating No. 2 Inlet Air Cleaner Bolts And Vacuum Hose With Clamp
    G06112113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Disconnect the 2 clamps.
    2. Remove the 3 bolts and air cleaner case sub-assembly.
    Fig 7: Locating Air Cleaner Case Sub-Assembly Bolts With Clamps
    G06112114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE AIR CLEANER BRACKET 
    1. Remove the 2 bolts and air cleaner bracket.
    Fig 8: Locating Air Cleaner Bracket Bolts
    G06112115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE NO. 1 INLET AIR CLEANER 
    1. Remove the bolt and No. 1 inlet air cleaner.
    Fig 9: Locating No. 1 Inlet Air Cleaner Bolt
    G06112116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Disconnect the level warning switch connector.
    2. Remove the bolt, and separate the brake master cylinder reservoir assembly.
    Fig 10: Locating Level Warning Switch Connector And Brake Master Cylinder Reservoir Assembly Bolt
    G06112117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE RESERVOIR BRACKET 
    1. Remove the 2 bolts and reservoir bracket.
    Fig 11: Locating Reservoir Bracket Bolts
    G06112118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Disconnect the No. 1 radiator hose.
    Fig 12: Locating No. 1 Radiator Hose
    G06112119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Disconnect the No. 2 radiator hose.
    Fig 13: Locating No. 2 Radiator Hose
    G06112120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. DISCONNECT INLET HEATER WATER HOSE 
    1. Disconnect the inlet heater water hose.
    Fig 14: Locating Inlet Heater Water Hose
    G06030147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Disconnect the outlet heater water hose.
    Fig 15: Locating Outlet Heater Water Hose
    G06030148Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the No. 1 fuel pipe clamp.
    2. Pinch the fuel tube connector and then pull out the fuel main tube.
    NOTE:
    • Check for dirt and foreign objects on the pipe and around the connector. Clean if necessary and then disconnect the connector.
    • Disconnect the connector by hand.
    • Do not bend, fold or rotate the nylon tube.
    • If the pipe and connector are stuck together, push and pull the connector until it becomes free.
    • Put the pipe and connector ends in vinyl bags to prevent damage and contamination.
    Fig 16: Locating No. 1 Fuel Pipe Clamp
    G06030149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. DISCONNECT INLET OIL COOLER HOSE 
    1. Disconnect the inlet oil cooler hose.
  41. DISCONNECT OUTLET OIL COOLER HOSE 
    1. Disconnect the outlet oil cooler hose.
    Fig 17: Locating Inlet Oil Cooler Hose And Outlet Oil Cooler Hose
    G06112124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the nut from the control shaft lever.
    2. Using a screwdriver, disengage the 4 claws, and disconnect the control cable with clip from the control cable bracket.
    3. Remove the clip.
    Fig 18: Locating Control Shaft Lever Nut And Control Cable Bracket Clip With Claws
    G06112125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. DISCONNECT ENGINE WIRE 
    1. Remove the No. 1 relay block cover.
      Fig 19: Identifying No. 1 Relay Block Cover
      G06112126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut, and disconnect the engine wire connector from the engine room relay block.
      Fig 20: Locating Nut And Engine Wire Connector
      G06112127Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.
      Fig 21: Separating Engine Wire From Engine Room Relay Block
      G06112128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the engine wire clamp.
      Fig 22: Identifying Engine Wire Clamp
      G06112129Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the engine wire clamp.
    6. Remove the bolt, and separate the ground cables.
      Fig 23: Locating Ground Cables Bolt
      G06112130Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the 2 bolts, and separate the ground cable.
      Fig 24: Locating Ground Cable Bolts
      G06112131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Remove the bolt, and separate the ground cable.
      Fig 25: Locating Ground Cable Bolt
      G06030207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Disconnect the 2 clamps, remove the nut and separate the positive (+) cable.
      Fig 26: Locating Positive (+) Cable Nut With Clamps
      G06030157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Disconnect the 4 ECM connectors, 2 junction block connectors and clamp.
      Fig 27: Locating ECM Connectors, Junction Block Connectors With Clamp
      G06112134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    11. Remove the 2 nuts and clamp, and separate the engine wire.
    Fig 28: Locating Engine Wire Nuts With Clamp
    G06112135Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the 2 bolts and No. 2 engine mounting stay RH.
    Fig 29: Locating No. 2 Engine Mounting Stay RH Bolts
    G06030159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE ENGINE MOVING CONTROL ROD 
    1. Remove the 4 bolts and engine moving control rod.
    Fig 30: Locating Engine Moving Control Rod Bolts
    G06030160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Disconnect the 2 union to check valve hoses.
  47. DISCONNECT SUCTION HOSE SUB-ASSEMBLY  (See REMOVAL )
  48. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY  (See REMOVAL )
  49. SECURE STEERING WHEEL  (See REMOVAL )
  50. REMOVE FRONT EXHAUST PIPE ASSEMBLY  (See REMOVAL )
    Fig 31: Locating Union To Check Valve Hoses
    G06112138Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH  (See REMOVAL )
  52. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT:

    Perform the same procedure as for the LH side.

  53. REMOVE FRONT AXLE HUB NUT LH  (See REMOVAL )
  54. REMOVE FRONT AXLE HUB NUT RH 

    HINT:

    Perform the same procedure as for the LH side.

  55. SEPARATE FRONT SPEED SENSOR LH  (See REMOVAL )
  56. SEPARATE FRONT SPEED SENSOR RH 

    HINT:

    Perform the same procedure as for the LH side.

  57. SEPARATE TIE ROD ASSEMBLY LH  (See REMOVAL )
  58. SEPARATE TIE ROD ASSEMBLY RH 

    HINT:

    Perform the same procedure as for the LH side.

  59. SEPARATE NO. 1 FRONT LOWER SUSPENSION ARM LH  (See REMOVAL )
  60. SEPARATE NO. 1 FRONT LOWER SUSPENSION ARM RH 

    HINT:

    Perform the same procedure as for the LH side.

  61. SEPARATE FRONT AXLE ASSEMBLY LH  (See REMOVAL )
  62. SEPARATE FRONT AXLE ASSEMBLY RH 

    HINT:

    Perform the same procedure as for the LH side.

  63. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY  (See REMOVAL )
  64. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the flywheel housing under cover.
    Fig 32: Locating Flywheel Housing Under Cover
    G06030201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT 
    1. Using SST, hold the crankshaft pulley.

      SST 09213-54015, 09330-00021, 91551 -80650 

      Fig 33: Holding Crankshaft Pulley Using SST
      G06030119Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 drive plate and torque converter clutch setting bolts.

      HINT:

      There is one black colored bolt.

  66. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine lifter.
      Fig 34: Locating Torque Converter Clutch Setting Bolt
      G06030200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 bolts, 2 nuts, and frame side rail plates RH and LH.
      Fig 35: Locating Frame Side Rail Plates Bolts And Nuts (RH And LH)
      G06112142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 6 bolts, 2 nuts, and front suspension member rear braces RH and LH.
    4. Operate the engine lifter, then remove the engine assembly with transaxle from the vehicle.
    NOTE: Make sure that the engine is clear of all wiring and hoses.
    Fig 36: Locating Front Suspension Member Rear Braces Bolts And Nuts (RH And LH)
    G06112143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. INSTALL ENGINE HANGERS 
    1. Install the 2 engine hangers with the 2 bolts as shown in the illustration.
      PART REFERENCE

      Item Part No.
      No. 1 engine hanger 12281-36020
      No. 2 engine hanger 12282-36020
      Bolt 91552-81040, 91552-81025

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      HINT:

      Fit the fork part of the No. 2 engine hanger onto the rib of the cylinder head.

    2. Attach the engine sling device and hang the engine with the chain block.
    Fig 37: Locating Engine Hangers Bolts
    G05997905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. REMOVE ENGINE WIRE 
  69. REMOVE V-RIBBED BELT  (See INSTALLATION )
  70. REMOVE GENERATOR ASSEMBLY  (See REMOVAL )
  71. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY  (See REMOVAL )
  72. REMOVE STARTER ASSEMBLY  (See REMOVAL )
  73. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH  (See REMOVAL )
  74. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH  (See DISASSEMBLY )
  75. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH  (See DISASSEMBLY )
  76. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. Remove the 3 bolts and drive shaft bearing bracket.
  77. REMOVE FRONT FRAME ASSEMBLY 
    1. Loosen the 3 nuts.
      Fig 38: Locating Drive Shaft Bearing Bracket Bolts
      G06030182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 39: Locating Front Frame Assembly Nuts
      G06112146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 hole plugs.
      Fig 40: Locating Hole Plugs
      G05640491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 9 nuts, and separate the front frame assembly.
    Fig 41: Locating Front Frame Assembly Nuts
    G05640492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE FRONT ENGINE MOUNTING INSULATOR 
    1. Remove the nut and front engine mounting insulator.
    Fig 42: Locating Front Engine Mounting Insulator Nut
    G06112149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE ENGINE MOUNTING INSULATOR LH 
    1. Remove the nut and engine mounting insulator LH.
    Fig 43: Locating Engine Mounting Insulator LH Nut
    G06112150Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. REMOVE ENGINE MOUNTING INSULATOR RH 
    1. Remove the nut and engine mounting insulator RH.
    Fig 44: Locating Engine Mounting Insulator RH Nut
    G06112151Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and engine mounting bracket RH.
  82. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY  (See DISASSEMBLY )
  83. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY  (See REMOVAL )
  84. INSTALL ENGINE ON ENGINE STAND 
    1. Install the engine onto an engine stand with the bolts.
    Fig 45: Locating Engine Mounting Bracket RH Bolts
    G06030177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. REMOVE ENGINE HANGERS 
    1. Remove the 2 bolts and No. 1 and No. 2 engine hangers.
scientia non olet · About LEMON Manuals