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Home >> Toyota >> 2019 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 11 (Engine Mechanical (1AR-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

WARNING: This page is about a different variant/trim than selected.
  1. PRECAUTION 
    WARNING:

    The engine assembly with transaxle 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. REMOVE FRONT WHEELS 
  7. 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]

  8. REMOVE NO. 1 ENGINE UNDER COVER 
    1. Remove the 6 bolts, 8 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 FLOOR UNDER COVER LH 

    Refer to PROCEDURE - Step 4

  11. SEPARATE FRONT FENDER LINER LH 
    1. Remove the 3 screws, 3 clips and separate the front fender liner LH.
  12. SEPARATE FRONT FENDER LINER RH 
    1. Remove the 2 screws, 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 1

  17. DRAIN AUTOMATIC TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 4

  18. SEPARATE BRAKE BOOSTER VACUUM EJECTOR 

    Refer to PROCEDURE - Step 3

  19. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [12/2013 - ]

  20. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4 , or refer to PROCEDURE - Step 4

  21. REMOVE RADIATOR SIDE DEFLECTOR SEAL LH 

    Refer to PROCEDURE - Step 1

  22. REMOVE RADIATOR SIDE SEAL RH 

    Refer to PROCEDURE - Step 2

  23. REMOVE COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 3

  24. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Lift the rear of the No. 1 engine cover sub-assembly to disengage it from the 2 pins.
      NOTE:

      Attempting to disengage both front and rear pins at the same time may cause the No. 1 engine cover sub-assembly to break.

      GTY425205Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Lift the front of the No. 1 engine cover sub-assembly to disengage it from the pin and remove it.
  25. REMOVE INLET AIR CLEANER ASSEMBLY 
    1. Remove the 2 bolts and inlet air cleaner assembly.
      GTY443465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 3

  27. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
    1. Remove the air cleaner filter element sub-assembly.
  28. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 
    1. Remove the 2 bolts and air cleaner case sub-assembly.
      GTY443475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 6

  30. REMOVE RESERVOIR BRACKET 

    Refer to PROCEDURE - Step 7

  31. REMOVE BATTERY 
    1. Loosen the nut, and disconnect the cable from the positive (+) battery terminal.
      GTY454661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Loosen the nut, and remove the bolt and battery clamp.
    3. Remove the battery and battery tray.
  32. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Remove the hose clamp to separate the air fuel ratio sensor wire from the No. 1 radiator hose.
      GTY440950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 1 radiator hose from the cylinder head sub-assembly.
  33. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.
      GTY318539Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. DISCONNECT INLET HEATER WATER HOSE 
    1. Slide the clip and disconnect the inlet heater water hose from the cylinder head sub-assembly.
      GTY439531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. DISCONNECT OUTLET HEATER WATER HOSE 
    1. Disengage the 2 claws and disconnect the inlet heater water hose and outlet heater water hose A.
      GTY433729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Inlet Heater Water Hose
      *2 Outlet Heater Water Hose A
      *3 Outlet Heater Water Hose B
    2. Slide the clip and disconnect the outlet heater water hose B from the cylinder head sub-assembly.
  36. DISCONNECT NO. 4 WATER BY-PASS HOSE 
    1. Slide the clip and disconnect the No. 4 water by-pass hose from the transmission oil cooler.
      GTY443473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. DISCONNECT NO. 3 WATER BY-PASS HOSE 
    1. Slide the clip and disconnect the No. 3 water by-pass hose from the transmission oil cooler.
      GTY443472Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 10

  39. DISCONNECT ENGINE WIRE 
    1. Remove the No. 1 relay block cover from the engine room relay block assembly.
    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.
  40. REMOVE NO. 1 AIR CLEANER BRACKET 
    1. Disconnect the 2 wire clamps.
      GTY371142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and No. 1 air cleaner bracket from the battery carrier.
  41. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. Remove the nut and disconnect the transmission control cable assembly from the control shaft lever.
      GTY384496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the clip and disconnect the transmission control cable assembly from the No. 1 control cable bracket.
      GTY438851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE NO. 2 ENGINE MOUNTING STAY RH 
    1. Remove the 2 bolts and No. 2 engine mounting stay RH.
      GTY447132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE ENGINE MOVING CONTROL ROD BRACKET 
    1. Remove the 4 bolts and engine moving control rod bracket.
      GTY447133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE ENGINE MOVING CONTROL ROD 
    1. Remove the bolt and engine moving control rod from the engine moving control rod bracket.
      GTY427946Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Perform this procedure only when replacement of the engine moving control rod is necessary.

  45. DISCONNECT UNION TO VACUUM TUBE HOSE 
    1. Slide the 2 clips and disconnect the 2 union to vacuum tube hoses from the No. 1 vacuum hose assembly.
      GTY384661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  47. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  48. DISCONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  49. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 5

  50. REMOVE FRONT AXLE SHAFT NUT 

    Refer to PROCEDURE - Step 2

  51. SEPARATE FRONT STABILIZER LINK ASSEMBLY 

    Refer to PROCEDURE - Step 7 , or refer to PROCEDURE - Step 7

  52. SEPARATE FRONT SPEED SENSOR 

    Refer to PROCEDURE - Step 3

  53. SEPARATE TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 17

  54. SEPARATE TIE ROD ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

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

    Refer to PROCEDURE - Step 8

  56. SEPARATE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 7

  57. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 9

  58. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING LH 

    Refer to PROCEDURE - Step 12

  59. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH 

    Refer to PROCEDURE - Step 10

  60. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 4

  61. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the flywheel housing under cover.
      GTY304888Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 

    Refer to PROCEDURE - Step 2

  63. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Place height adjustment attachments and plate lift attachments in the positions shown in the illustration and set an engine lifter underneath the engine assembly with transaxle.
      GTY432606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Attachment Installation Position
      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 sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.
      • 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.
    2. Remove the 6 bolts, 2 nuts and frame side rail plate RH and frame side rail plate LH.
      GTY438219Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
      *b 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.
    5. Using an engine sling device and engine lift, secure the engine assembly with transaxle.
  64. INSTALL ENGINE HANGERS 
    1. Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts as shown in the illustration.
      GTY433621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
      PART NO.

      Item Part No.
      No. 1 Engine Hanger 12281-36020
      No. 2 Engine Hanger 12282-36021
      Bolt 91552-81040 or 91552-81025

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

  65. REMOVE ENGINE WIRE 
    1. Remove the engine wire from the engine assembly with transaxle.
  66. REMOVE V-RIBBED BELT 

    See step  1

  67. REMOVE COMPRESSOR ASSEMBLY WITH PULLEY 

    Refer to PROCEDURE - Step 6

  68. REMOVE GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 4

  69. REMOVE FRONT FRAME ASSEMBLY 
    1. Remove the nut and separate the engine mounting insulator LH.
      GTY318528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and separate the front engine mounting insulator.
      GTY427010Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the nut and separate the engine mounting insulator RH.
      GTY318530Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the front frame assembly.
    5. Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle on a flat level surface.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.
      • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.
  70. 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.
      GTY443481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and front engine mounting insulator.
      GTY440292Courtesy 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.
      GTY443480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and engine mounting insulator LH.
      GTY318527Courtesy 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.
      GTY443483Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 nuts and engine mounting insulator RH.
      GTY318521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  73. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. Remove the 3 bolts and drive shaft bearing bracket.
      GTY251253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE ENGINE MOUNTING BRACKET RH 
    1. Remove the 3 bolts and engine mounting bracket RH.
      GTY304895Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 8

  76. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  2

  77. INSTALL ENGINE TO ENGINE STAND 
    1. Install the engine assembly to an engine stand.
      NOTE:
      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.
      • 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.
  78. REMOVE ENGINE HANGERS 
    1. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.
      GTY437090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
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