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Home >> Toyota >> 2017 >> Highlander XLE, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 139 (Hybrid Transaxle (P313) (Service Information)) >> Hybrid Vehicle Transaxle >> 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. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  3. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 2

  4. REMOVE FRONT WHEELS 
  5. REMOVE NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 11

  6. REMOVE NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 12

  7. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 13

  8. SEPARATE FRONT FENDER LINER LH 

    Refer to PROCEDURE - Step 14

  9. SEPARATE FRONT FENDER LINER RH 

    Refer to PROCEDURE - Step 15

  10. REMOVE FRONT FENDER APRON SEAL LH 

    Refer to PROCEDURE - Step 16

  11. REMOVE FRONT FENDER APRON SEAL RH 

    Refer to PROCEDURE - Step 17

  12. REMOVE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to REMOVAL [11/2016 - ]

  13. REMOVE INVERTER TRAY BRACKET SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 14

  14. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to REMOVAL [11/2016 - ]

  15. REMOVE NO. 2 SURGE TANK STAY 

    Refer to PROCEDURE - Step 7

  16. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 8

  17. DISCONNECT NO. 1 MOTOR COOLING HOSE 

    Refer to PROCEDURE - Step 25

  18. DISCONNECT NO. 3 MOTOR COOLING HOSE 

    Refer to PROCEDURE - Step 26

  19. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 46

  20. DISCONNECT WIRE HARNESS 
    1. Disconnect the shift lever position sensor connector.
      GTY570552Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Shift Lever Position Sensor Connector *b Generator Resolver Sensor Connector
      *c Motor Resolver Sensor Connector *d Motor Temperature Sensor Connector
    2. Disconnect the generator resolver sensor connector.
    3. Disconnect the motor resolver sensor connector.
    4. Disconnect the motor temperature sensor connector.
    5. Disengage the 8 clamps.
    6. Remove the bolt and disconnect the No. 3 earth wire.
      GTY445106Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 15

  22. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 22

  23. REMOVE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to REMOVAL [02/2014 - ]

  24. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 4

  25. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9

  26. SEPARATE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 

    Refer to PROCEDURE - Step 31

  27. SEPARATE ENGINE MOUNTING INSULATOR LH 

    Refer to PROCEDURE - Step 32

  28. SEPARATE ENGINE MOUNTING INSULATOR RH 

    Refer to PROCEDURE - Step 33

  29. SEPARATE REAR ENGINE MOUNTING INSULATOR ASSEMBLY 

    Refer to PROCEDURE - Step 34

  30. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Disconnect the air fuel ratio sensor (for Bank 1) connector.
      GTY714112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the hose clamp and 3 wire harness clamps.
      GTY727863Courtesy 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.
  31. INSTALL ENGINE HANGER 
    1. Remove the bolt and disconnect the wire harness.
      GTY714057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install SST (engine hanger attachment) to the cylinder head RH with the 2 bolts.
      GTY686775Courtesy 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.

    3. Install SST (collar) and the No. 1 engine hanger to SST (engine hanger attachment) with the bolt.
      GTY696852Courtesy 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.

    4. Disengage the clamp to disconnect the wire harness from the wire harness bracket.
      GTY679759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the bolt and wire harness bracket from the engine assembly.
    6. 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.

  32. INSTALL ENGINE SUPPORT BRIDGE 
    1. Disengage the air conditioner tube and accessory assembly from the piping clamp.
      GTY714056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install SST to the vehicle body as shown in the illustration.
      GTY693734Courtesy 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 the 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.
    3. 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
    4. Install the chain block to the sling bracket.
      GTY737494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Chain Block *b Sling Bracket
      *c Fuse Shackle *d Shackle (A)
    5. 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.
    6. Connect the division bar to the No. 1 engine hanger with the shackle (A).
      GTY699798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger *2 No. 2 Engine Hanger
      *a Division Bar *b Shackle (A)
    7. Connect the division bar to the No. 2 engine hanger with the 2 shackles (A).
    8. 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 - -
    9. 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.
      GTY722711Courtesy 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.
      GTY686380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Main Beam
      *b Dimension (A)
      *c Dimension (B)
    10. Tighten the 6 wing bolts and 2 bolts.
      GTY728074Courtesy 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
    11. Tighten the chain block assembly until it cannot be moved any further by hand.
      GTY671700Courtesy 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.
  33. 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.
      GTY734462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09727-00110 
    3. Using the ratchet buckle, tighten the 2 belts until there is no slack.
      GTY736347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Ratchet Buckle - -
  34. REMOVE FRONT FRAME ASSEMBLY 

    Refer to PROCEDURE - Step 39

  35. REMOVE ENGINE MOUNTING INSULATOR RH 
    1. Remove the nut and engine mounting insulator RH from the engine mounting bracket RH.
      GTY728046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. 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.
      GTY739588Courtesy 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 assembly 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) 

  37. REMOVE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 
    1. Remove the bolt and front engine mounting insulator assembly from the front engine mounting bracket.
      GTY740061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE ENGINE MOUNTING INSULATOR LH 
    1. Remove the bolt and HV transaxle mass damper.
      GTY728071Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut and engine mounting insulator LH from the automatic transaxle assembly.
      GTY728047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. 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.

  40. REMOVE BELT 
    1. Remove SST from the vehicle body.
      GTY737796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the bolt and wire harness clamp bracket from the hybrid vehicle transaxle assembly.
      GTY438893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE MOTOR CABLE BRACKET 
    1. Remove the bolt and motor cable bracket from the hybrid vehicle transaxle assembly.
      GTY438884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE NO. 2 TRANSMISSION CONTROL CABLE BRACKET 
    1. Remove the bolt and No. 2 transmission control cable bracket from the hybrid vehicle transaxle assembly.
      GTY439079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE NO. 3 TRANSMISSION CONTROL CABLE BRACKET 
    1. Remove the bolt and No. 3 transmission control cable bracket from the hybrid vehicle transaxle assembly.
      GTY589619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE OUTLET OIL COOLER TUBE SUB-ASSEMBLY 
    1. Using a 17 mm union nut wrench, disconnect the outlet oil cooler tube sub-assembly from the oil cooler tube union.
      GTY607971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Oil Cooler Tube Union
      *2 Outlet Oil Cooler Tube Sub-assembly
      *3 No. 2 Oil Cooler Tube Clamp
    2. Remove the bolt, No. 2 oil cooler tube clamp and outlet oil cooler tube sub-assembly from the No. 1 oil cooler tube clamp.
    3. Remove the oil cooler tube union and gasket from the hybrid vehicle transaxle assembly.
      GTY439082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the bolt and No. 1 oil cooler tube clamp from the hybrid vehicle transaxle assembly.
      GTY589617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE NO. 1 TRANSMISSION CONTROL CABLE BRACKET 
    1. Remove the 2 bolts and No. 1 transmission control cable bracket from the hybrid vehicle transaxle assembly.
      GTY589616Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE NO. 3 AUTOMATIC TRANSMISSION CASE COVER 
    1. Remove the 2 bolts, clip and No. 3 automatic transmission case cover from the hybrid vehicle transaxle assembly.
      GTY453723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE FRONT ENGINE MOUNTING BRACKET 
    1. Remove the 3 bolts and front engine mounting bracket from the hybrid vehicle transaxle assembly.
      GTY589613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the 2 bolts and flywheel housing under cover.
      GTY686606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE MANIFOLD STAY 

    Refer to PROCEDURE - Step 18

  51. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY 
    1. Using a transmission jack attachment, set the hybrid vehicle transaxle assembly on a transmission jack.
      NOTE:
      • Secure the hybrid vehicle transaxle assembly to the transmission jack using a suitable adapter, such as a rope or attachment.
      • To prevent the motor water jacket cover assembly from deforming, do not place any attachments under the motor water jacket cover assembly of the hybrid vehicle transaxle assembly.
      • Hold the engine assembly with a suitable adapter, such as a rope, during the operation.
      • Do not damage the hybrid vehicle transaxle assembly.
    2. Remove the 10 bolts and hybrid vehicle transaxle assembly from the engine assembly.
      GTY714108Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • To avoid damaging the 2 knock pins, do not pry between the hybrid vehicle transaxle assembly and the engine assembly.
      • To prevent the splines of the transmission input damper assembly from becoming misaligned, do not allow the hybrid vehicle transaxle assembly to hit the transmission input damper assembly during hybrid vehicle transaxle assembly removal and installation.
  52. REMOVE HYBRID TRANSAXLE MASS DAMPER 
    1. Remove the hybrid transaxle mass damper and gasket from the hybrid vehicle transaxle assembly.
      GTY714110Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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