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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. PRECAUTION 
    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 - ]

  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  3. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 2

  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. REMOVE FRONT WHEELS 
  6. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [12/2013 - ]

  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  8. REMOVE NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 8

  9. REMOVE NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 9

  10. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 3

  11. SEPARATE FRONT FENDER LINER LH 

    Refer to PROCEDURE - Step 11

  12. SEPARATE FRONT FENDER LINER RH 

    Refer to PROCEDURE - Step 12

  13. REMOVE FRONT FENDER APRON SEAL LH 

    Refer to PROCEDURE - Step 13

  14. REMOVE FRONT FENDER APRON SEAL RH 

    Refer to PROCEDURE - Step 14

  15. DRAIN ENGINE COOLANT 

    Refer to PROCEDURE - Step 1

  16. DRAIN AUTOMATIC TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 3

  17. REMOVE STARTER ASSEMBLY (w/ Stop And Start System) 

    Refer to REMOVAL [11/2016 - ]

  18. REMOVE STARTER ASSEMBLY (w/o Stop And Start System) 

    Refer to REMOVAL [11/2016 - ]

  19. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 6

  20. DISCONNECT ENGINE WIRE 
    1. Disconnect the park/neutral position switch assembly connector.
      GTY732881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Transmission Wire Connector
      *b Park/Neutral Position Switch Assembly Connector
      *1 Engine Wire
      *2 Earth Wire
    2. Disengage the claw, rotate the lever and disconnect the connector of the transmission wire connector.
    3. Remove the 2 bolts and nut, and disconnect the engine wire from the automatic transaxle case sub-assembly.
    4. Remove the bolt to separate the earth wire.
    5. Disengage the clamp to separate the engine wire.
  21. SEPARATE BREATHER PLUG HOSE 
    1. Disengage the 3 hose clamps to separate the breather plug hose.
      GTY718291Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT NO. 4 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 13

  23. DISCONNECT NO. 3 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 14

  24. REMOVE RADIATOR PIPE ASSEMBLY 
    1. Remove the bolt and radiator pipe assembly from the automatic transaxle assembly.
      GTY704519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Radiator Pipe Assembly
  25. DISCONNECT OUTLET NO. 1 OIL COOLER HOSE 

    Refer to PROCEDURE - Step 17

  26. DISCONNECT NO. 1 TRANSMISSION OIL COOLER HOSE 

    Refer to PROCEDURE - Step 18

  27. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 29

  28. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to REMOVAL [11/2016 - ]

  29. DISCONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 8

  30. DISCONNECT PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 9

  31. REMOVE NO. 2 SURGE TANK STAY 

    Refer to PROCEDURE - Step 10

  32. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 11

  33. REMOVE AIR SURGE TANK TO INTAKE MANIFOLD GASKET 

    Refer to PROCEDURE - Step 12

  34. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Disconnect the air fuel ratio sensor (for Bank 1) connector.
      GTY687122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the hose clamp and 3 wire harness clamps.
      GTY701901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hose Clamp
      *b Wire Harness Clamp
    3. Remove the bolt and wire harness clamp bracket from the cylinder head RH.
  35. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  36. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side) 

    Refer to PROCEDURE - Step 9

  37. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 10

  38. REMOVE MANIFOLD STAY 

    Refer to PROCEDURE - Step 5

  39. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 6

  40. REMOVE EXHAUST MANIFOLD TO HEAD GASKET (for Bank 1) 

    Refer to PROCEDURE - Step 7

  41. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  42. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

  43. REMOVE FRONT AXLE SHAFT NUT 

    Refer to PROCEDURE - Step 7

  44. SEPARATE FRONT SPEED SENSOR 

    Refer to PROCEDURE - Step 8

  45. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 5

  46. SEPARATE TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 6

  47. SEPARATE TIE ROD ASSEMBLY RH 

    HINT: 

    Use the same procedure as for the LH side.

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

    Refer to PROCEDURE - Step 8

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

    HINT: 

    Use the same procedure as for the LH side.

  50. SEPARATE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 7

  51. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 13

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

    Refer to PROCEDURE - Step 18

  53. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH 

    Refer to PROCEDURE - Step 14

  54. SEPARATE TRANSMISSION OIL THERMOSTAT 

    Refer to PROCEDURE - Step 48

  55. SEPARATE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 

    Refer to PROCEDURE - Step 49

  56. SEPARATE ENGINE MOUNTING INSULATOR LH 

    Refer to PROCEDURE - Step 50

  57. SEPARATE ENGINE MOUNTING INSULATOR RH 

    Refer to PROCEDURE - Step 51

  58. SEPARATE REAR ENGINE MOUNTING INSULATOR ASSEMBLY 

    Refer to PROCEDURE - Step 52

  59. INSTALL ENGINE HANGER 
    1. Install SST (engine hanger attachment) to the cylinder head RH with the 2 bolts.
      GTY740604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09940-30010 
        1. 91671-10825

      Bolt (A) 

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

      Bolt (B) 

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      Item Part No.
      Bolt (A) 91671-10825
      Bolt (B) 91551-80620
      NOTE:

      Do not use any bolts other than the specified bolts.

    2. Install SST (collar) and No. 1 engine hanger to SST (engine hanger attachment) with the bolt.
      GTY708441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger
      • SST: 09940-30010 
        1. 09941-03010

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

      Item Part No.
      No. 1 Engine Hanger 12281-36020
      Bolt 91552-81050
      NOTE:

      Do not use any bolts other than the specified bolt.

    3. Install the No. 2 engine hanger to the cylinder head LH with the 2 bolts.

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

      Item Part No.
      No. 2 Engine Hanger 12282-31100
      Bolt 91671-10825
      GTY730161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Engine Hanger
      NOTE:

      Do not use any bolts other than the specified bolts.

  60. INSTALL ENGINE SUPPORT BRIDGE 
    1. Install SST to the vehicle body as shown in the illustration.
      GTY718469Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Support Shaft *b Front Side Member
      *c Cloth *d Front Side
      *e Front Suspension Nut - -
      • SST: 09940-10020 
      WARNING:
      • Make sure that no oil or grease is on the front side member, and set the support shaft on the level surface of the front side member.
        GTY614759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Support Shaft
        *b Front Side Member
      • The engine support bridge may fall off if there is any oil or grease on the front side member or it is installed on an unlevel surface.
      NOTE:
      • Prevent SST from contacting the vehicle body exterior and windshield glass.
      • To prevent damage to the engine hood, place pieces of cloth between the engine hood and SST.
      • Lightly shake SST by hand to make sure it is securely installed before performing work.
    2. Turn the threaded portion of each support shaft to adjust its height until the sub beams are parallel to the ground.
      GTY649983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Support Shaft
      *b Sub Beam
      *c Front Side Member
      *d Threaded Portion
    3. Install the chain block to the sling bracket.
      GTY708388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Chain Block *b Sling Bracket
      *c Fuse Shackle *d Shackle (A)
    4. Install the division bar to the chain block with the fuse shackle and shackle (A).
      WARNING:
      • Make sure the fuse shackle is on the chain block side and the shackle (A) is on the division bar side as shown in the illustration so that the fuse bolt is visible and can be checked for deformation easily.
        GTY668065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Fuse Shackle
        *b Shackle (A)
      • If the fuse shackle is installed upside down, deformation of the fuse bolt will not be visible and cannot be used to tell if the load capacity of the engine support bridge has been exceeded. If the load capacity is exceeded, it may cause the engine support bridge to damage the vehicle and the engine assembly with automatic transaxle assembly may fall.
      • Make sure that the fuse bolt of the fuse shackle is free of damage, such as deformation or cracks. If damaged, replace the fuse shackle.
        GTY631927Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Fuse Shackle
        *b Fuse Bolt
      • If a deformed fuse bolt is used, it cannot be used to tell if the load capacity of the engine support bridge has been exceeded. If the load capacity is exceeded, it may cause the engine support bridge to damage the vehicle and the engine assembly with transaxle assembly may fall.
    5. Connect the division bar to the No. 1 engine hanger with the shackle (A).
      GTY714442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger
      *a Division Bar *b Shackle (A)
    6. Connect the division bar to the No. 2 engine hanger with the 2 shackles (A).
    7. Make sure the distance between the chain block assembly and suspension ring is 120 mm (4.72 in.) or more.
      GTY708658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Chain Block Assembly *b Suspension Ring
      *c 120 mm or more - -
    8. Adjust the position of the chain block assembly so that the chain is perpendicular to the main beam and sub beams as shown in the illustration.
      GTY735412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Chain Block Assembly *b Main Beam
      *c Sub Beam *d Dimension (A)
      *e Dimension (B) *f Correct
      *g Incorrect *h Right to Left Adjustment
      *i Front to Rear Adjustment - -
      WARNING:
      • To prevent the engine assembly with automatic transaxle assembly from falling, make sure that the length of dimension (A) and dimension (B) are equal.
      • Do not perform any procedures if the length of dimension (A) and dimension (B) are not equal.
      • Performing any procedure when the length of dimension (A) and dimension (B) are not equal may cause the engine assembly with automatic transaxle assembly and engine support bridge to fall, possibly causing serious injury.
      GTY691769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Main Beam
      *b Dimension (A)
      *c Dimension (B)
    9. Tighten the 6 wing bolts and 2 bolts.
      GTY718246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

      WARNING:
      • Do not perform any procedures before tightening the bolts to the specified torque.
      • Performing procedures without tightening the bolts to the specified torque, may cause the engine support bridge to fall.
      GTY638600Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    10. Tighten the chain block assembly until it cannot be moved any further by hand.
      GTY637287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      WARNING:
      GTY647185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 41 N*m (418 kgf*cm, 30 ft.*lbf) or more
      • When suspending the engine assembly with automatic transaxle assembly, do not tighten the chain block assembly more than 41 N*m (418 kgf*cm, 30 ft.*lbf).
      • Tightening the chain block assembly more than 41 N*m (418 kgf*cm, 30 ft.*lbf) will cause the load capacity (400 kg (881.8 lb)) to be exceeded and may cause damage to the engine support bridge and vehicle body.
  61. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the 2 bolts and flywheel housing under cover from the automatic transaxle case sub-assembly.
      GTY686606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 
    1. Turn the crankshaft to gain access to the 6 drive plate and torque converter assembly setting bolts and remove each drive plate and torque converter assembly setting bolt while holding the crankshaft pulley bolt with a wrench.
      GTY722726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      There will be one black colored drive plate and torque converter assembly setting bolt.

  63. INSTALL BELT 
    1. Remove the bolt and nut and disconnect the windshield washer jar assembly from the vehicle body.
      GTY710369Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Install SST to the vehicle body as shown in the illustration.
      GTY712684Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09727-00110 
    3. Using the ratchet buckle, tighten the 2 belts until there is no slack.
      GTY710080Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Ratchet Buckle - -
  64. REMOVE FRONT FRAME ASSEMBLY 

    Refer to PROCEDURE - Step 56

  65. REMOVE ENGINE MOUNTING INSULATOR RH 
    1. Remove the nut and engine mounting insulator RH from the engine mounting bracket RH.
      GTY718236Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSTALL ENGINE SUPPORT BAR 
    1. Install SST (support bar) to the engine mounting bracket RH with the stud bolt and nut as shown in the illustration.
      GTY739666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Engine Mounting Bracket RH - -
      *a SST (Belt) *b SST (Support Bar)
      *c SST (Nut) *d SST (Spacer 20)
      *e SST (Spacer 30) *f SST (Bolt 40)
      *g SST (Bolt 90) *h SST (Washer)
      *i Stud Bolt - -
      • SST: 09940-20011 
        1. 09941-02010
        2. 09941-02020
        3. 09941-02030
        4. 09941-02040
        5. 09941-02050
        6. 09941-02060
        7. 09941-02070
      WARNING:

      To prevent the engine with automatic transaxle assembly from falling while servicing, do not remove SST (belt).

      HINT: 

      Tighten the nut by hand.

    2. Install SST (support bar) to the vehicle body with the 2 bolts.

      Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf) 

  67. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 
    1. Remove the bolt and front engine mounting insulator assembly from the front engine mounting bracket.
      GTY718257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. REMOVE ENGINE MOUNTING INSULATOR LH 
    1. Remove the nut and engine mounting insulator LH from the automatic transaxle assembly.
      GTY718258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. SUPPORT ENGINE ASSEMBLY 
    1. Set an engine lifter.
      GTY718254Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:

      To prevent the engine assembly with automatic transaxle assembly from falling while servicing, do not remove SST.

      NOTE:

      Make sure that there is clearance between the engine oil pan assembly and engine lifter.

  70. REMOVE BELT 
    1. Remove SST from the vehicle body.
      GTY720306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY 
    1. Support the automatic transaxle assembly with a transmission jack.
      NOTE:

      Secure the automatic transaxle assembly to the transmission jack using a suitable adapter, such as a rope or attachments.

    2. Remove the 11 bolts and automatic transaxle assembly.
      GTY694227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      To prevent damage to the knock pins, do not pry between the automatic transaxle assembly and engine assembly.

  72. DISCONNECT INLET NO. 2 OIL COOLER HOSE 

    Refer to PROCEDURE - Step 15

  73. DISCONNECT OUTLET NO. 3 OIL COOLER HOSE 

    Refer to PROCEDURE - Step 16

  74. REMOVE NO. 1 OIL COOLER TUBE SUB-ASSEMBLY WITHOUT HOSE 

    Refer to PROCEDURE - Step 19

  75. REMOVE TRANSMISSION OIL COOLER 

    Refer to PROCEDURE - Step 20

  76. REMOVE FRONT ENGINE MOUNTING BRACKET 
    1. Remove the 4 bolts and front engine mounting bracket from the automatic transaxle assembly.
      GTY718261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. REMOVE ENGINE MOUNTING BRACKET LH 
    1. Remove the 3 bolts and engine mounting bracket LH from the automatic transaxle case sub-assembly.
      GTY732601Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET 
    1. Remove the 2 bolts and No. 1 transmission control cable bracket from the automatic transaxle case sub-assembly.
      GTY694230Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the bolt and wire harness clamp bracket from the automatic transaxle case sub-assembly.
      GTY729766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. REMOVE TRANSMISSION CASE PLUG ASSEMBLY 
    1. Remove the transmission case plug assembly from the automatic transaxle assembly.
      GTY728062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. REMOVE BREATHER PLUG HOSE 
    GTY707003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a screwdriver, remove the breather plug hose from the No. 1 breather plug (ATM).
      NOTE:

      Be careful not to damage the No. 1 breather plug (ATM).

    2. Remove the breather plug sub-assembly from the breather plug hose.
      GTY696664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Breather Plug Sub-assembly
      *2 Breather Plug Hose
      NOTE:

      Be careful not to damage the breather plug sub-assembly.

  82. REMOVE TORQUE CONVERTER ASSEMBLY 
    1. Remove the torque converter assembly from the automatic transaxle assembly.
  83. INSPECT TORQUE CONVERTER ASSEMBLY 

    See step  1

  84. INSPECT DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  2

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