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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 80 (Hybrid Transaxle System (P810) - Service Information) >> Hybrid Vehicle Transaxle >> Removal [11/2023 - ] >> Procedure

Removal [11/2023 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. PERFORM RESOLVER INITIALIZATION 
    NOTE:

    If it is necessary to replace the hybrid vehicle transaxle assembly, make sure to perform resolver initialization before starting work.

    Refer to UTILITY [11/2023 - ]

  2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 

    Refer to REMOVAL [11/2023 - ]

  3. REMOVE FUEL DELIVERY GUARD 

    Refer to PROCEDURE - Step 39

  4. INSTALL ENGINE HANGERS 

    Refer to PROCEDURE - Step 40

  5. REMOVE STEERING GEAR HEAT INSULATOR 

    Refer to PROCEDURE - Step 9

  6. DISCONNECT ENGINE WIRE 
    1. Rear side:
      1. Disconnect the wire harness connector from the rack and pinion power steering gear assembly.
        GTY917463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        HINT: 

        Release the lock before rotating the lock lever.

      2. Remove the 2 bolts to disconnect the engine wire.
      3. Disengage the 6 clamps to disconnect the engine wire.
    2. Front side:
      1. Remove the 2 bolts to disconnect the engine wire.
        GTY917461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCONNECT HV AIR CONDITIONING WIRE 
    1. Remove the 2 bolts to disconnect the HV air conditioning wire from the hybrid vehicle transaxle assembly.
      GTY943659Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the guide to disconnect the HV air conditioning wire from the hybrid vehicle transaxle assembly.
  8. DISCONNECT WATER HOSE 
    1. Disengage the clamp to disconnect the water hose.
      GTY917432Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE TRANSAXLE UNDER STOPPER BRACKET 
    1. Remove the 4 bolts and transaxle under stopper bracket from the hybrid vehicle transaxle assembly.
      GTY917431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE STARTER HOLE INSULATOR 
    1. Remove the 2 bolts and starter hole insulator from the engine assembly.
      GTY1179359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE FLYWHEEL HOUSING SIDE COVER 
    1. Remove the flywheel housing side cover from the engine assembly.
      GTY943658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FRONT FRAME ASSEMBLY 

    Refer to PROCEDURE - Step 7

  13. REMOVE FRONT ENGINE MOUNTING INSULATOR 

    Refer to PROCEDURE - Step 49

  14. REMOVE FRONT ENGINE MOUNTING BRACKET 
    1. Remove the 3 bolts and front engine mounting bracket from the hybrid vehicle transaxle assembly.
      GTY917429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE REAR ENGINE MOUNTING INSULATOR 

    Refer to PROCEDURE - Step 50

  16. REMOVE REAR ENGINE MOUNTING BRACKET 
    1. Remove the 4 bolts and rear engine mounting bracket from the hybrid vehicle transaxle assembly.
      GTY917428Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY 
    1. Remove the 8 bolts and hybrid vehicle transaxle assembly from the engine assembly.
      GTY917427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • To avoid damaging the knock pins, do not pry between the hybrid vehicle transaxle assembly and 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.
  18. REMOVE MOTOR CABLE 

    See step  2

  19. DISCONNECT OUTLET MOTOR HOSE 

    See step  12

  20. REMOVE MOTOR COOLING COOLER 
    1. Slide the clip and disconnect the No. 1 motor cooling hose from the tube connector.
      GTY1178948Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and motor cooling cooler from the No. 1 transmission control cable bracket.
      GTY1178947Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE MOTOR COOLING PIPE ASSEMBLY 
    1. Remove the oil cooler union bolt and gasket to disconnect the motor cooling pipe assembly from the hybrid vehicle transaxle assembly.
      GTY1179006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and motor cooling pipe assembly from the hybrid vehicle transaxle assembly.
  22. 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.
      GTY917442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 3 INVERTER BRACKET 
    1. Remove the 6 bolts and No. 3 inverter bracket from the hybrid vehicle transaxle assembly.
      GTY943661Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TRANSMISSION WIRE 
    1. Disconnect the connector.
      GTY917440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and transmission wire from the hybrid vehicle transaxle assembly.
  25. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Remove the 4 bolts and 4 wire harness clamp brackets from the hybrid vehicle transaxle assembly.
      GTY917439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE TRANSAXLE HOUSING PLUG 
    1. Remove the transaxle housing plug and gasket from the hybrid vehicle transaxle assembly.
      GTY917438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE STUD BOLT 
    1. Using a E10 "TORX" socket wrench, remove the 2 stud bolts from the hybrid vehicle transaxle assembly.
      GTY943660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE TRANSAXLE BREATHER PLUG 

    HINT: 

    Perform this procedure only when replacement of the transaxle breather plug is necessary.

    1. Remove the transaxle breather plug from the hybrid vehicle transaxle assembly.
      GTY917437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE TUBE CONNECTOR 

    HINT: 

    Perform this procedure only when replacement of the tube connector or O-ring is necessary.

    1. Remove the tube connector from the hybrid vehicle transaxle assembly.
      GTY1179004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the tube connector.
  30. REMOVE OUTLET MOTOR HOSE 

    HINT: 

    Perform this procedure only when replacement of the outlet motor hose or motor cooling pipe assembly is necessary.

    1. Slide the clip and remove the outlet motor hose from the motor cooling pipe assembly.
      GTY1179005Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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