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Home >> Toyota >> 2016 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 166 (Engine Mechanical (2GR-FXE) (Service Information) (Hybrid)) >> Engine Assembly & Engine Under Cover >> Removal [11/2015 - 11/2016] >> Procedure

Removal [11/2015 - 11/2016]: Procedure

WARNING: This page is about a different variant/trim than selected.
  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.
    • The vehicle has a hybrid system that operates at voltages up to 650 V. The hybrid system uses an HV battery that contains an electrolyte which is a strong alkali solution that includes potassium hydroxide. Be sure to follow the instructions in this service information to handle the system correctly. Failure to do so may result in serious injury or electrocution.

      Refer to PRECAUTION [02/2014 - 11/2016]

    NOTE:

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

    Refer to PRECAUTION [02/2014 - 11/2016]

  2. REMOVE RADIATOR SIDE DEFLECTOR SEAL LH 

    Refer to PROCEDURE - Step 1

  3. REMOVE RADIATOR SIDE SEAL RH 

    Refer to PROCEDURE - Step 2

  4. REMOVE COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 3

  5. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  6. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [02/2014 - 11/2016]

  7. PLACE FRONT WHEELS FACING STRAIGHT AHEAD 
  8. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 3

  9. REMOVE SERVICE PLUG GRIP 

    Refer to REMOVAL [02/2014 - ]

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

    Refer to PROCEDURE - Step 4

  14. SEPARATE FRONT FENDER LINER LH 
    1. Remove the 3 screws and 3 clips and separate the front fender liner LH.
  15. SEPARATE FRONT FENDER LINER RH 
    1. Remove the 3 screws and 3 clips and separate the front fender liner RH.
  16. REMOVE FRONT FENDER APRON SEAL LH 
    1. Remove the 2 bolts, clip and front fender apron seal LH.
      GTY432405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FRONT FENDER APRON SEAL RH 
    1. Remove the 2 bolts, clip and front fender apron seal RH.
      GTY452273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 1

  19. DRAIN ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 2

  20. DRAIN COOLANT (for Inverter) 

    Refer to PROCEDURE - Step 2

  21. DRAIN HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 1

  22. 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.
      GTY455024Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Raise the V-bank cover sub-assembly to disengage the 2 rear retainers 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.

  23. REMOVE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to REMOVAL [02/2014 - 11/2016]

  24. REMOVE INVERTER TRAY BRACKET SUB-ASSEMBLY 
    1. Disengage the 2 clamps and disconnect the water by-pass hose.
      GTY445158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 bolts and inverter tray bracket sub-assembly.
  25. DISCONNECT NO. 1 MOTOR COOLING HOSE 
    1. Slide the clip and disconnect the No. 1 motor cooling hose.
      GTY445157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. DISCONNECT NO. 3 MOTOR COOLING HOSE 
    1. Slide the clip and disconnect the No. 3 motor cooling hose.
      GTY445162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Separate the No. 1 radiator hose from the radiator pipe clamp.
      GTY445161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 1 radiator hose from the water outlet.
  28. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Disengage the clamp and disconnect the No. 2 radiator hose.
      GTY445160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.
  29. DISCONNECT WATER HOSE SUB-ASSEMBLY 
    1. Slide the clip and disconnect the water hose sub-assembly from the water outlet.
      GTY445159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. DISCONNECT NO. 3 AIR CONDITIONING ACCESSORY ASSEMBLY 
    1. Slide the clip and disconnect the No. 3 air conditioning accessory assembly from the water inlet pipe.
      GTY455012Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY 
    1. Slide the clip and disconnect the fuel vapor feed hose assembly from the purge valve (purge VSV).
      GTY294858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Disengage the clamp and disconnect the wire harness from the brake master cylinder reservoir assembly.
      GTY445105Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts and separate the brake master cylinder reservoir assembly.
  33. REMOVE RESERVOIR BRACKET 
    1. Remove the 2 bolts.
      GTY445104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 3 clamps and disconnect the No. 2 earth wire from the reservoir bracket.
    3. Remove the 2 nuts and reservoir bracket.
      GTY445111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE NO. 2 ENGINE MOUNTING STAY RH (for Engine Mounting Stay Side) 
    1. Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.
      GTY298825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE ENGINE MOVING CONTROL ROD BRACKET 
    1. Remove the 4 bolts and engine moving control rod bracket with engine moving control rod.
      GTY445112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. 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.
      GTY446923Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Engine Moving Control Rod
      *2 No. 3 Engine Mounting Stay RH
      *3 Engine Moving Control Rod Bracket
  37. REMOVE ECM 

    Refer to REMOVAL [02/2014 - 11/2016]

  38. DISCONNECT ENGINE WIRE 
    1. Disconnect the 3 connectors.
      GTY445109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp and disconnect the engine wire from the engine room relay block assembly.
    3. Disengage the 5 clamps.
      GTY445108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and disconnect the engine wire.
    5. Remove the bolt and disconnect the No. 3 earth wire.
      GTY445106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  40. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  41. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the No. 1 fuel pipe clamp.
      GTY296676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tube connector from the fuel main tube by hand. When the fuel tube connector and the fuel main tube are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube 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 fuel tube connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the fuel main tube and fuel tube connector.
      • Do not use any tools to separate the fuel main tube and fuel tube 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 fuel tube connector ends with plastic bags to prevent damage and contamination.
      • If the fuel main tube and fuel tube 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.
  42. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  43. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 11

  44. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 4

  45. REMOVE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to REMOVAL [02/2014 - ]

  46. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Move the shift lever to N.
    2. Remove the nut and separate the transmission control cable assembly from the transmission control shaft lever.
      GTY439205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. 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.
    4. Using a screwdriver, disengage the 2 claws and remove the clip from the transmission control cable assembly.
      GTY444212Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the transmission control cable assembly from the No. 2 transmission control cable bracket and 2 No. 3 transmission control cable brackets.
      GTY423870Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 2 Transmission Control Cable Bracket
      *2 No. 3 Transmission Control Cable Bracket
  47. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET 
    1. Remove the 2 nuts and No. 1 exhaust pipe support bracket.
      GTY445107Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the 2 bolts and flywheel housing under cover.
      GTY303690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. 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 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.
      GTY437052Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Attachment Installation Position
    2. Remove the 6 bolts, 2 nuts and frame side plate RH and frame side plate LH.
      GTY452497Courtesy 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.
  50. INSTALL ENGINE HANGERS 
    1. Disconnect the wire harness from the wire harness bracket.
      GTY305732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and wire harness bracket.
    3. 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)

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

    4. 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.
  51. REMOVE FRONT FRAME ASSEMBLY 
    1. Disengage the 2 clamps.
      GTY445116Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and separate the front engine mounting insulator.
      GTY295042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt and HV transaxle mass damper.
      GTY445120Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut and separate the engine mounting insulator LH.
      GTY445121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the nut and separate the engine mounting insulator RH.
      GTY296589Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 3 bolts and separate the rear engine mounting insulator assembly.
      GTY445115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the front frame assembly.
  52. REMOVE FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Remove the hole plug from the front frame assembly.
      GTY445118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and front engine mounting insulator.
      GTY299619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. 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.
      GTY445117Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. 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.
      GTY452159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. 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
  56. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine assembly with transaxle.
  57. REMOVE RADIATOR PIPE CLAMP 
    1. Disconnect the No. 2 air fuel ratio sensor wire from the radiator pipe clamp.
      GTY430403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and radiator pipe clamp.
  58. REMOVE NO. 2 EARTH WIRE 
    1. Remove the bolt and No. 2 earth wire.
      GTY445122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE MANIFOLD STAY 

    Refer to PROCEDURE - Step 6

  60. REMOVE NO. 2 TRANSMISSION CONTROL CABLE BRACKET 

    Refer to PROCEDURE - Step 6

  61. REMOVE NO. 3 AUTOMATIC TRANSMISSION CASE COVER 

    Refer to PROCEDURE - Step 10

  62. REMOVE FRONT ENGINE MOUNTING BRACKET 

    Refer to PROCEDURE - Step 11

  63. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 14

  64. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY 

    See step  2

  65. REMOVE FLYWHEEL SUB-ASSEMBLY 

    See step  3

  66. 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.
  67. REMOVE ENGINE HANGERS 
    1. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.
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