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Removal [11/2016 - ]: Procedure

WARNING: This page is about a different car, the 2019 Toyota Highlander, 2018 Toyota Highlander, and 2017 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.
  1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  2. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [11/2016 - ]

  3. PRECAUTION 
    WARNING:

    The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

    NOTE:

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Refer to PRECAUTION [11/2016 - ]

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [11/2016 - ]

  5. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  6. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 2

  7. REMOVE FRONT WHEELS 
  8. REMOVE NO. 1 ENGINE UNDER COVER 
    1. Remove the 8 bolts, 6 screws, 3 clips and No. 1 engine under cover.
  9. REMOVE NO. 2 ENGINE UNDER COVER 
    1. Remove the 2 bolts, 2 screws, clip and No. 2 engine under cover.
  10. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 3

  11. SEPARATE FRONT FENDER LINER LH 
    1. Remove the 3 screws and 3 clips and separate the front fender liner LH.
  12. SEPARATE FRONT FENDER LINER RH 
    1. Remove the 3 screws and 3 clips and separate the front fender liner RH.
  13. REMOVE FRONT FENDER APRON SEAL LH 
    1. Remove the 2 bolts, clip and front fender apron seal LH.
      GTY686609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FRONT FENDER APRON SEAL RH 
    1. Remove the 2 bolts, clip and front fender apron seal RH.
      GTY730910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 1

  16. DRAIN ENGINE COOLANT 

    Refer to PROCEDURE - Step 1

  17. DRAIN AUTOMATIC TRANSAXLE FLUID (for 2WD) 

    Refer to PROCEDURE - Step 3

  18. DRAIN AUTOMATIC TRANSAXLE FLUID (for AWD) 

    Refer to PROCEDURE - Step 3

  19. DRAIN TRANSFER OIL (for AWD) 

    Refer to PROCEDURE - Step 1

  20. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [12/2013 - ]

  21. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  22. REMOVE RADIATOR SIDE DEFLECTOR SEAL LH 

    Refer to PROCEDURE - Step 1

  23. REMOVE RADIATOR SIDE SEAL RH 

    Refer to PROCEDURE - Step 2

  24. REMOVE COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 3

  25. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Hold the rear of the V-bank cover sub-assembly and raise it to disengage the 2 rear clips.
      GTY711586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Raise the V-bank cover sub-assembly to disengage the 2 front clips and remove the V-bank cover sub-assembly.
      NOTE:

      Attempting to disengage both front and rear clips at the same time may cause the V-bank cover sub-assembly to break.

  26. REMOVE BATTERY 
    1. Disconnect the cable from the positive (+) battery terminal.
      GTY711584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut and bolt.
    3. Remove the battery clamp, battery clamp bolt, battery and battery tray.
  27. REMOVE INLET AIR CLEANER ASSEMBLY 
    1. Remove the 2 bolts and inlet air cleaner assembly.
      GTY736412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 
    1. Disconnect the mass air flow meter sub-assembly connector.
      GTY667752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the wire harness clamp.
    3. Disengage the No. 1 fuel vapor feed hose from the air cleaner hose assembly.
      GTY700873Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Fuel Vapor Feed Hose
      *2 No. 2 Ventilation Hose
    4. Slide the clip and disconnect the No. 2 ventilation hose from the air cleaner hose assembly.
    5. Remove the 2 bolts.
      GTY686610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Loosen the hose clamp and remove the air cleaner assembly with air cleaner hose.
      NOTE:

      Make sure the air cleaner support is attached to the vehicle body.

  29. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Disconnect the reservoir level switch connector and remove the bolt from the brake master cylinder reservoir assembly.
      GTY442348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Master Cylinder Reservoir Assembly
      *2 Reservoir Bracket
    2. Move the brake master cylinder reservoir assembly as shown in the illustration to disengage the 2 claws, and separate it.
  30. REMOVE RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 7

  31. REMOVE AIR CLEANER BRACKET 
    1. Disengage the clamp.
      GTY711591Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and air cleaner bracket from the vehicle body.
  32. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the bolt, 2 nuts and No. 2 engine mounting stay RH from the engine mounting insulator sub-assembly RH.
      GTY722269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  33. REMOVE ENGINE MOVING CONTROL ROD BRACKET 
    1. Remove the 4 bolts and engine moving control rod bracket with engine moving control rod from the front No. 1 engine mounting bracket LH and vehicle body.
      GTY710979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE ENGINE MOVING CONTROL ROD 

    HINT: 

    Perform this procedure only when replacement of the engine moving control rod or No. 3 engine mounting stay RH is necessary.

    1. Remove the 2 bolts, engine moving control rod and No. 3 engine mounting stay RH from the engine moving control rod bracket.
      GTY444190Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Disconnect the purge VSV (purge valve) connector.
    2. Slide the clip and disconnect the No. 1 fuel vapor feed hose from the No. 1 vacuum switching valve.
      GTY711590Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. DISCONNECT UNION TO CHECK VALVE HOSE 
    1. Slide the clip and disconnect the union to check valve hose from the intake air surge tank assembly.
      GTY702447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp from the union to check valve hose.
  37. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 1 radiator hose from the water outlet.
      GTY711545Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the No. 1 radiator hose from the radiator pipe clamp.
  38. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.
      GTY711544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. DISCONNECT WATER HOSE SUB-ASSEMBLY 
    1. Slide the 2 clips and disconnect the 2 water hose sub-assemblies.
      GTY686410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp from the water hose sub-assembly.
  40. DISCONNECT NO. 3 WATER BY-PASS HOSE 
    1. Slide the clip and disconnect the No. 3 water by-pass hose from the radiator pipe assembly.
      GTY711546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. DISCONNECT NO. 4 WATER BY-PASS HOSE 
    1. Slide the clip and disconnect the No. 4 water by-pass hose from the radiator pipe assembly.
      GTY711547Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the No. 2 fuel pipe clamp from the No. 1 fuel pipe clamp.
      GTY773460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Fuel Pipe Camp Type A
      *B Fuel Pipe Camp Type B
    2. Remove the No. 1 fuel pipe clamp from the fuel tube connector.
      GTY768559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Fuel Pipe Camp Type A
      *B Fuel Pipe Camp Type B
    3. Disconnect the No. 2 fuel tube sub-assembly (for Direct Injection).
      1. Disconnect the No. 2 fuel tube sub-assembly from the fuel pipe.
        GTY735808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Refer to PRECAUTION [11/2016 - ]

    4. Disconnect the fuel tube sub-assembly (for Port Injection).
      1. Disconnect the fuel tube sub-assembly from the fuel pipe.
        GTY708832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Refer to PRECAUTION [11/2016 - ]

  43. DISCONNECT NO. 1 TRANSMISSION OIL COOLER HOSE 
    1. Slide the clip and disconnect the No. 1 transmission oil cooler hose from the transmission oil thermostat.
      GTY711542Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. DISCONNECT OUTLET NO. 1 OIL COOLER HOSE 
    1. Slide the clip and disconnect the outlet No. 1 oil cooler hose from the transmission oil thermostat.
      GTY711543Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. DISCONNECT TRANSMISSION OIL THERMOSTAT 
    1. Remove the bolt and disconnect the transmission oil thermostat from the oil cooler stay.
      GTY686411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE STARTER ASSEMBLY 

    for w/ Stop And Start System: Refer to PROCEDURE - Step 10

    for w/o Stop And Start System: Refer to PROCEDURE - Step 10

  47. DISCONNECT ENGINE WIRE 
    1. Remove the No. 1 relay block cover from the engine room relay block assembly.
      GTY686607Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and separate the earth wire.
      GTY711592Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nut from the engine room relay block assembly.
    4. Disengage the 2 clamps to disconnect the engine wire.
    5. Disengage 2 the claws to disconnect the engine wire.
    6. Disconnect the 4 connectors from the engine room relay block assembly.
    7. Pull up the lock lever while pushing the lock on the lever to disconnect the ECM connector.
      GTY711589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      After disconnecting the ECM connector, make sure that dirt, water or other foreign matter does not contact the connecting part of the ECM connector.

    8. Disengage the 2 clamps.
    9. Remove the bolt and separate the No. 3 earth wire.
      GTY735809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. GTY686605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the clamp and disconnect the engine wire.

    11. Remove the nut and engine room main wire with engine wire from the positive (+) battery terminal.
    12. Disengage the 2 claws to disconnect the engine room main wire from the engine wire.
      GTY671789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the clip from the transmission control shaft lever as shown in the illustration.
      GTY722554Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, disengage the 4 claws and disconnect the transmission control cable assembly with the clip from the No. 1 transmission control cable bracket.
    3. Using a screwdriver, disengage the 2 claws and disconnect the clip from the transmission control cable assembly.
      GTY444212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the transmission control cable assembly from the No. 3 transmission control cable bracket.
      GTY738854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY (for 2WD) 

    Refer to PROCEDURE - Step 5

  50. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 5

  51. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  52. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  53. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) 

    Refer to REMOVAL [11/2016 - ]

  54. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  55. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 10

  56. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET 
    1. Remove the 2 nuts and No. 1 exhaust pipe support bracket from the oil pan sub-assembly.
      GTY736409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE EXHAUST MANIFOLD 

    Refer to REMOVAL [11/2016 - ]

  58. REMOVE FRONT AXLE SHAFT NUT 

    Refer to PROCEDURE - Step 7

  59. SEPARATE FRONT SPEED SENSOR LH 

    Refer to PROCEDURE - Step 8

  60. SEPARATE FRONT SPEED SENSOR RH 

    HINT: 

    Use the same procedure as for the LH side.

  61. SEPARATE TIE ROD ASSEMBLY LH 

    for 2WD: Refer to PROCEDURE - Step 6

    for AWD: Refer to PROCEDURE - Step 6

  62. SEPARATE TIE ROD ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  63. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  64. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  65. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  66. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  67. SEPARATE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 7

  68. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 13

  69. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) 

    Refer to PROCEDURE - Step 14

  70. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING (for LH Side) 

    Refer to PROCEDURE - Step 18

  71. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the 2 bolts and flywheel housing under cover.
      GTY686606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for 2WD) 

    Refer to PROCEDURE - Step 62

  73. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for AWD) 

    Refer to PROCEDURE - Step 68

  74. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Place height adjustment attachments and plate lift attachments, set an engine lifter underneath the engine assembly with transaxle.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle level.
      • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
      • To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.
    2. Remove the 6 bolts, 2 nuts, frame side rail plate RH and frame side rail plate LH from the front frame assembly and vehicle body.
      GTY690023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    3. Remove the 6 bolts, 2 nuts, front suspension member rear brace RH and front suspension member rear brace LH from the front frame assembly and vehicle body.
    4. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle body.
      NOTE:
      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
      • While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.
  75. INSTALL ENGINE HANGERS 
    1. Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.
      GTY732836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1
      *B for Bank 2
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 

      HINT: 

      No. 1 Engine Hanger 12281-31121
      No. 2 Engine Hanger 12282-31100
      Bolt 91671-10825
    2. Using an engine sling device and engine lifter, secure the engine assembly with transaxle.
      NOTE:
      • Adjust the angle of the sling device carefully to prevent damage or deformation to the engine hangers or engine assembly.
      • Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
  76. REMOVE ENGINE WIRE 
    1. Disconnect all clamps and connectors and remove the engine wire from the engine assembly with transaxle.
  77. REMOVE FRONT NO. 1 STABILIZER BRACKET LH (for AWD) 

    Refer to PROCEDURE - Step 6

  78. REMOVE FRONT NO. 1 STABILIZER BRACKET RH (for AWD) 

    HINT: 

    Perform the same procedure as for the LH side.

  79. REMOVE FRONT STABILIZER BAR (for AWD) 

    Refer to PROCEDURE - Step 5

  80. REMOVE STEERING LINK ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 15

  81. REMOVE FRONT FRAME ASSEMBLY 
    1. Remove the bolt and disconnect the front engine mounting insulator assembly.
      GTY736280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut and disconnect the engine mounting insulator LH.
      GTY710977Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nut and disconnect the engine mounting insulator RH.
      GTY710975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts and disconnect the rear engine mounting insulator assembly.
      GTY713581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for 2WD
      *B for AWD
    5. Remove the front frame assembly.
  82. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for AWD) 

    Refer to PROCEDURE - Step 17

  83. REMOVE TRANSFER STIFFENER PLATE RH 

    Refer to PROCEDURE - Step 71

  84. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY 

    for 2WD: Refer to PROCEDURE - Step 71

    for AWD: Refer to PROCEDURE - Step 79

  85. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and engine mounting bracket RH from the cylinder block sub-assembly.
      GTY710973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  2

  87. INSTALL ENGINE ASSEMBLY TO ENGINE STAND 
    1. Install the engine assembly to an engine stand.
  88. REMOVE ENGINE HANGERS 
    1. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and cylinder head LH.
  89. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 

    HINT: 

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

    1. Remove the hole plug from the front frame assembly.
      GTY671721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and front engine mounting insulator assembly.
      GTY671720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. REMOVE ENGINE MOUNTING INSULATOR LH 

    HINT: 

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

    1. Remove the 2 hole plugs from the front frame assembly.
      GTY443354Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and engine mounting insulator LH.
      GTY710971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  91. REMOVE ENGINE MOUNTING INSULATOR RH 

    HINT: 

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

    1. Remove the 2 hole plugs from the front frame assembly.
      GTY443371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and engine mounting insulator RH.
      GTY710995Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  92. REMOVE REAR ENGINE MOUNTING INSULATOR ASSEMBLY 

    HINT: 

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

    1. Remove the 2 hole plugs from the front frame assembly.
      GTY366410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts and rear engine mounting insulator assembly.
      GTY706196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for 2WD
      *B for AWD
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