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Home >> Toyota >> 2017 >> Highlander XLE, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 121 (Engine Mechanical (2GR-FXS) - Service Information - (Hybrid) (1 Of 2)) >> Engine Assembly & Engine Under Cover >> Removal [11/2016 - ] >> Procedure

Removal [11/2016 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 
    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 [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 [11/2016 - ]

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

    Refer to PROCEDURE - Step 2

  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 3

  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.
      GTY686609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FRONT FENDER APRON SEAL RH 
    1. Remove the 2 bolts, clip and front fender apron seal RH.
      GTY730910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 1

  19. DRAIN ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 1

  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 rear clips.
      GTY711257Courtesy 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.

  23. REMOVE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to REMOVAL [11/2016 - ]

  24. REMOVE INVERTER TRAY BRACKET SUB-ASSEMBLY 
    1. Disengage the 2 clamps to disconnect the water by-pass hose from the inverter tray bracket sub-assembly.
      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 from the inlet oil cooler tube sub-assembly.
      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 from the outlet oil cooler tube sub-assembly.
      GTY445162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Separate the No. 1 radiator hose from the radiator pipe clamp.
      GTY736344Courtesy 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. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.
      GTY711267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. DISCONNECT WATER HOSE SUB-ASSEMBLY 
    1. Slide the clip and disconnect the water hose sub-assembly from the water outlet.
      GTY711261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Separate the water hose sub-assembly from the clamp.
  30. DISCONNECT HEATER WATER HOSE 
    1. Slide the clip and disconnect the heater water hose from the water inlet pipe.
      GTY711263Courtesy 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).
      GTY679758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Disengage the clamp to 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 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.
      GTY728300Courtesy 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 [11/2016 - ]

  38. DISCONNECT ENGINE WIRE 
    1. Disconnect the 3 connectors.
      GTY703650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the claw to 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. 2 fuel pipe clamp from the fuel pipe clamp.
      GTY762900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Fuel Pipe Camp Type A
      *B Fuel Pipe Camp Type B
    2. Remove the fuel pipe clamp from the fuel tube connector.
      GTY768558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Fuel Pipe Camp Type A
      *B Fuel Pipe Camp Type B
    3. Disconnect the fuel tube sub-assembly (for Direct Injection).
      1. Disconnect the fuel tube sub-assembly from the fuel pipe.
        GTY704116Courtesy 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.
        GTY734788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Refer to PRECAUTION [11/2016 - ]

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

    Refer to PROCEDURE - Step 15

  43. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 22

  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 bolts 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.
      GTY686606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front frame assembly level, set an engine lifter underneath the engine assembly with transaxle and front frame assembly.
      NOTE:
      • 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.
      GTY720830Courtesy 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.
  50. DISCONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 11

  51. REMOVE NO. 2 EGR PIPE 

    Refer to PROCEDURE - Step 15

  52. REMOVE NO. 2 EGR PIPE GASKET 

    Refer to PROCEDURE - Step 16

  53. DISCONNECT WATER BY-PASS HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 14

  54. DISCONNECT NO. 6 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 15

  55. REMOVE EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 16

  56. REMOVE MANIFOLD STAY 

    Refer to PROCEDURE - Step 18

  57. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 20

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

    Refer to PROCEDURE - Step 21

  59. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 25

  60. REMOVE NO. 2 MANIFOLD STAY 

    Refer to PROCEDURE - Step 26

  61. REMOVE EXHAUST MANIFOLD ASSEMBLY LH (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 27

  62. REMOVE EXHAUST MANIFOLD TO HEAD GASKET (for Bank 2) 

    Refer to PROCEDURE - Step 28

  63. INSTALL ENGINE HANGERS 
    1. Disengage the clamp to disconnect the wire harness from the wire harness bracket.
      GTY679759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and wire harness bracket from the engine assembly.
    3. Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.

      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
      GTY674385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1
      *B for Bank 2
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
    4. Using an engine sling device and engine lifter, secure the engine assembly with transaxle.
      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 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.
  64. REMOVE ENGINE WIRE 
    1. Disconnect all clamps and connectors and remove the engine wire from the engine assembly with transaxle.
  65. REMOVE FRONT FRAME ASSEMBLY 
    1. Remove the bolt and separate the front engine mounting insulator from the front engine mounting bracket.
      GTY728313Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and HV transaxle mass damper.
      GTY728312Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nut and separate the engine mounting insulator LH.
      GTY445121Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut and separate the engine mounting insulator RH.
      GTY728305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 3 bolts and separate the rear engine mounting insulator.
      GTY728304Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the front frame assembly.
  66. REMOVE MOTOR CABLE BRACKET 

    Refer to PROCEDURE - Step 42

  67. REMOVE NO. 3 AUTOMATIC TRANSMISSION CASE COVER 

    Refer to PROCEDURE - Step 47

  68. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 51

  69. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY 
    1. Using height adjustment attachments and plate lift attachments, place the engine assembly on a flat level surface.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, keep the engine assembly horizontal.
      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments under the No. 2 oil pan sub-assembly of the engine assembly.
      • Using an engine sling device and engine lifter, secure the engine assembly before servicing.
    2. Remove the transmission input damper assembly.

      See step  2

  70. REMOVE FLYWHEEL SUB-ASSEMBLY 

    See step  3

  71. INSTALL ENGINE ASSEMBLY TO ENGINE STAND 
    1. Install the engine assembly to an engine stand.
  72. REMOVE ENGINE HANGERS 
    1. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.
  73. REMOVE FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. GTY671721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the hole plug from the front frame assembly.

    2. GTY740113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 3 nuts and front engine mounting insulator from the front frame assembly.

  74. REMOVE REAR ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. GTY366410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 2 hole plugs from the front frame assembly.

    2. GTY301206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 2 nuts and rear engine mounting insulator from the front frame assembly.

  75. 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.
      GTY728302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. 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.
      GTY728303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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