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Home >> Toyota >> 2016 >> Highlander LE Plus, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2GR-FE) (Service Information) (Except Hybrid) (1 Of 2) >> Engine Assembly & Engine Under Cover >> Removal [12/2013 - 11/2016] >> Procedure

Removal [12/2013 - 11/2016]: Procedure

  1. PRECAUTION 
    WARNING:

    The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the service information, 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 [12/2013 - 11/2016]

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  3. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [12/2013 - 11/2016]

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

    Refer to PROCEDURE - Step 3

  6. 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 [12/2013 - 11/2016]

  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.
      GTY432405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE FRONT FENDER APRON SEAL RH 
    1. Remove the 2 bolts, clip and front fender apron seal RH.
      GTY452273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 1

  16. DRAIN ENGINE COOLANT 

    Refer to PROCEDURE - Step 2

  17. DRAIN AUTOMATIC TRANSAXLE FLUID (for 2WD) 

    Refer to PROCEDURE - Step 4

  18. DRAIN AUTOMATIC TRANSAXLE FLUID (for AWD) 

    Refer to PROCEDURE - Step 4

  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 , or 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 front retainers.
      GTY363564Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Raise the V-bank cover sub-assembly to disengage the rear retainer to remove the V-bank cover sub-assembly.
      NOTE:

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

  26. REMOVE INLET AIR CLEANER ASSEMBLY 
    1. Remove the 2 bolts and inlet air cleaner assembly.
      GTY444183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the air hose from the 2 hose clamps.
  27. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 3

  28. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
    1. Remove the air cleaner filter element sub-assembly from the air cleaner case sub-assembly.
  29. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Remove the 2 bolts and air cleaner case sub-assembly.
      GTY454809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE BATTERY 
    1. Disconnect the cable from the positive (+) battery terminal.
      GTY444182Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut and bolt.
    3. Remove the battery clamp, battery clamp bolt, battery and battery tray.
  31. 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.
  32. REMOVE RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 7

  33. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.
      GTY444181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE ENGINE MOVING CONTROL ROD BRACKET 
    1. Remove the 4 bolts and engine moving control rod bracket with engine moving control rod.
      GTY444180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. 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
  36. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Slide the clip and disconnect the No. 1 fuel vapor feed hose from the No. 1 vacuum switching valve.
      GTY382032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. 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.
      GTY452122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 1 radiator hose from the water outlet.
      GTY301402Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the No. 1 radiator hose from the radiator pipe clamp.
  39. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.
      GTY384569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. DISCONNECT INLET HEATER WATER HOSE 
    1. Slide the clip and disconnect the inlet heater water hose from the water inlet.
      GTY452323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Slide the clip and disconnect the outlet heater water hose from the water outlet.
      GTY432631Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the No. 1 fuel pipe clamp.
      GTY384652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the connector from the fuel main tube by hand. When the connector and the fuel main tube are stuck, push and pull the connector to release it. Pull the connector off of the fuel main tube carefully.
      GTY448432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Push
      Pull
      NOTE:
      • Check for any dirt and foreign matter in the fuel main tube and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the fuel main tube and connector.
      • Do not use any tools to separate the fuel main tube and connector.
      • Do not forcibly bend or twist the nylon tube.
      • Check for any dirt and foreign matter on the tube seal surface. Clean if necessary.
      • Cover the fuel main tube and connector ends with plastic bags to prevent damage and contamination.
      • If the fuel main tube and connector are stuck together, pinch the fuel main tube between your fingers and turn it carefully to free it. Then disconnect the fuel main tube.
  43. DISCONNECT NO. 1 OUTLET OIL COOLER HOSE 
    1. GTY437936Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Slide the clip and disconnect the No. 1 outlet oil cooler hose.

  44. DISCONNECT NO. 1 INLET OIL COOLER HOSE 
    1. GTY453478Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Slide the clip and disconnect the No. 1 inlet oil cooler hose.

  45. REMOVE STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 10

  46. DISCONNECT ENGINE WIRE 
    1. Remove the No. 1 relay block cover from the engine room relay block assembly.
      GTY452324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and separate the earth wire.
      GTY440820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nut from the engine room relay block assembly.
    4. Disconnect the 3 wire clamps.
    5. Disconnect the 4 connectors from the engine room relay block assembly.
      GTY443464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a screwdriver, disengage the claw and separate the engine wire 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.
      GTY443463Courtesy 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 wire harness clamps.
  47. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the nut from the transmission control shaft lever.
      GTY423470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, disengage the 4 claws, separate the transmission control cable assembly with clip from the No. 1 transmission control cable bracket.
      GTY449978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the clip from the transmission control cable assembly.
  48. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) 

    Refer to REMOVAL [12/2013 - 11/2016]

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

    Refer to PROCEDURE - Step 5

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

    Refer to PROCEDURE - Step 9

  51. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 10

  52. REMOVE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to REMOVAL [12/2013 - 11/2016]

  53. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY (for 2WD) 

    Refer to PROCEDURE - Step 4

  54. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 4

  55. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  56. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  57. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Upper Side) 
    1. Remove the 2 bolts and No. 1 exhaust pipe support bracket.
      GTY454811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the 2 bolts and flywheel housing under cover.
      GTY445401Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for 2WD) 

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 2

  61. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set an engine lifter.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.
      • Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
      • To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle.
      • Do not perform any procedure while the engine assembly with transaxle is suspended because doing so may cause the engine assembly with transaxle to drop, resulting in injury. However, the engine assembly with transaxle needs to be suspended when it is installed to or removed from an engine stand.
      GTY444191Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 6 bolts, 2 nuts and frame side plate RH and frame side plate LH.
      GTY429926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    3. Remove the 6 bolts, 2 nuts and front suspension member rear brace RH and front suspension member rear brace LH.
    4. Operate the engine lifter and remove the engine assembly with transaxle from the vehicle.
      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.
  62. INSTALL ENGINE HANGERS 
    1. Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.
      GTY447246Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1
      *B for Bank 2
      *1 No. 1 Engine Hanger (Part No. 12281-31120)
      *2 No. 2 Engine Hanger (Part No. 12282-31100)
      *3 Bolt (Part No. 91671-10825) or (Part No. 90119-A0117)

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

    2. Attach the engine sling device and hang the engine assembly with transaxle with the chain block.
      NOTE:
      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.
      • Do not perform any procedure while the engine assembly with transaxle is suspended because doing so may cause the engine assembly with transaxle to drop, resulting in injury. However, the engine assembly with transaxle needs to be suspended when it is installed to or removed from an engine stand.
  63. REMOVE V-RIBBED BELT 

    See step  4

  64. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY 

    Refer to PROCEDURE - Step 6

  65. REMOVE FRONT NO. 1 STABILIZER BRACKET LH (for AWD) 

    Refer to PROCEDURE - Step 4

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

    HINT: 

    Perform the same procedure as for the LH side.

  67. REMOVE FRONT STABILIZER BAR (for AWD) 

    Refer to PROCEDURE - Step 10

  68. REMOVE STEERING LINK ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 11

  69. REMOVE FRONT FRAME ASSEMBLY 
    1. Disconnect the 2 clamps.
      GTY451901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and disconnect the front engine mounting insulator assembly.
      GTY454812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nut and disconnect the engine mounting insulator LH.
      GTY318500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut and disconnect the engine mounting insulator RH.
      GTY322708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 bolts and disconnect the rear engine mounting insulator assembly.
      GTY432415Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the front frame assembly.
  70. 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.
      GTY443372Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and front engine mounting insulator assembly.
      GTY444194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. 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.
      GTY318507Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. 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.
      GTY318491Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. 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.
      GTY301206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE MANIFOLD STAY 

    Refer to PROCEDURE - Step 6

  75. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine assembly with transaxle.
  76. REMOVE RADIATOR PIPE CLAMP (for 2WD) 

    Refer to PROCEDURE - Step 9

  77. REMOVE RADIATOR PIPE CLAMP (for AWD) 

    Refer to PROCEDURE - Step 13

  78. REMOVE TRANSFER STIFFENER PLATE RH (for AWD) 

    Refer to PROCEDURE - Step 14

  79. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) 

    Refer to PROCEDURE - Step 10

  80. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 15

  81. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  3

  82. INSTALL ENGINE TO ENGINE STAND 
    1. Install the engine assembly to an engine stand.
      NOTE:
      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.
      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.
  83. REMOVE ENGINE HANGERS 
    1. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.
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