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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 23 (Engine Mechanical System (A25A-FXS) - Service Information (2 Of 3)) >> Engine Assembly >> Removal [11/2023 - ] >> Procedure

Removal [11/2023 - ]: Procedure

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

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal.

    Refer to BEFORE DISCONNECTING BATTERY [11/2023 - ]

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  3. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [11/2023 - ]

  4. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  5. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 3

  6. REMOVE FRONT WHEELS 

    Refer to REMOVAL [10/2022 - ]

  7. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 
    1. Remove the 4 screws and front wheel opening extension pad LH.
      GTY940496Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 
    1. Remove the 4 screws and front wheel opening extension pad RH.
      GTY903155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE NO. 1 ENGINE UNDER COVER 
    1. Remove the 3 bolts, 8 screws, 2 clips and No. 1 engine under cover.
      GTY930276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
  10. REMOVE NO. 2 ENGINE UNDER COVER ASSEMBLY 
    1. Remove the 2 bolts, 2 screws, 6 clips and No. 2 engine under cover assembly.
      GTY897460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Clip
  11. REMOVE FRONT FENDER APRON SEAL LH 
    1. Remove the 2 bolts, clip and front fender apron seal LH.
      GTY903186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE FRONT FENDER APRON SEAL RH 
    1. Remove the 2 bolts, clip and front fender apron seal RH.
      GTY940503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE HEADLIGHT ASSEMBLY LH 

    Refer to REMOVAL [11/2023 - ]

  14. REMOVE FRONT BUMPER LOWER ABSORBER 

    Refer to PROCEDURE - Step 26

  15. REMOVE NO. 2 FRONT BUMPER REINFORCEMENT 

    Refer to PROCEDURE - Step 28

  16. DRAIN ENGINE COOLANT (for Engine) 

    Refer to PROCEDURE - Step 1

  17. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 2

  18. DRAIN HYBRID TRANSAXLE FLUID 

    Refer to PROCEDURE - Step 5

  19. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 
    1. Lift the front of the No. 1 engine cover sub-assembly to disengage the 2 clips, and then lift the rear of the No. 1 engine cover sub-assembly to disengage the clip and remove the No. 1 engine cover sub-assembly.
      NOTE:

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

      GTY880732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE INVERTER WITH CONVERTER ASSEMBLY 

    Refer to REMOVAL [11/2023 - ]

  21. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY 
    1. Disengage the clamp.
      GTY880729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the fuel vapor feed hose assembly from the No. 1 vacuum switching valve assembly.
  22. DISCONNECT OUTLET HEATER WATER HOSE B 
    1. Pull out the retainer to disengage the lock claws and pull off the outlet heater water hose B from the No. 2 water by-pass pipe sub-assembly.
      GTY866973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Pull out
      Pull off
    2. Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.
    3. Cover the disconnected No. 2 water by-pass pipe sub-assembly and outlet heater water hose B connector with plastic bags to prevent damage and contamination.
  23. DISCONNECT INLET HEATER WATER HOSE B 
    1. Pull out the retainer to disengage the lock claws and pull off the inlet heater water hose B from the flow shutting valve (water by-pass hose assembly).
      GTY888165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Pull out
      Pull off
    2. Check that there is no foreign matter on the sealing surfaces of the disconnected water lines. Clean them if necessary.
    3. Cover the disconnected flow shutting valve (water by-pass hose assembly) and inlet heater water hose B connector with plastic bags to prevent damage and contamination.
  24. DISCONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Remove the No. 1 fuel pipe clamp from the fuel tube connector.
      GTY880730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the fuel tube sub-assembly.
      1. Disconnect the fuel tube sub-assembly from the fuel pipe.
        GTY935533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

        Refer to PRECAUTION [11/2023 - ]

  25. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Disengage the clamp.
      GTY880718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the No. 1 radiator hose from the water outlet.
  26. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet with thermostat sub-assembly.
      GTY880719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY 
    1. Remove the bolt and disconnect the discharge hose sub-assembly from the compressor with motor assembly.
      GTY916141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the discharge hose sub-assembly.
      NOTE:

      Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.

  28. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  29. DISCONNECT NO. 5 INVERTER COOLING HOSE 
    1. Slide the clip and disconnect the No. 5 inverter cooling hose from the motor cooling cooler.
      GTY880722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. DISCONNECT WIRE HARNESS 

    HINT: 

    After disconnecting the wire harness, secure it with tape or equivalent to keep it out of the way.

    1. Disengage the 3 claws and remove the No. 1 relay block cover from the No. 1 engine room relay block and No. 1 junction block assembly.
      GTY880723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the nut from the No. 1 engine room relay block and No. 1 junction block assembly.
      GTY880724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the 4 connectors from the No. 1 engine room relay block and No. 1 junction block assembly.
    4. Using a screwdriver, disengage the claw and disconnect the wire harness from the No. 1 engine room relay block and No. 1 junction block assembly.
    5. Remove the 2 bolts and disconnect the earth wire.
      GTY880725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. DISCONNECT NO. 4 WATER BY-PASS HOSE 
    1. Slide the clip and disconnect the No. 4 water by-pass hose from the No. 3 water by-pass pipe.
      GTY880734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 5

  33. REMOVE FRONT FLOOR COVER LH 
    1. Remove the 5 bolts, 3 screws, 2 clips (A) and clip (B) and disengage the 5 clamps to remove the front floor cover LH from the vehicle body.
      GTY914896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Clip
  34. REMOVE FRONT FLOOR COVER RH 
    1. Remove the 3 bolts, 3 screws and clip and disengage the 4 clamps to remove the front floor cover RH from the vehicle body.
      GTY844337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
      Clip
  35. REMOVE FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 

    Refer to PROCEDURE - Step 11

  36. REMOVE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to REMOVAL [11/2023 - ]

  37. DISCONNECT HEATER WATER HOSE (w/ Exhaust Heat Recirculation System) 
    1. Slide the clip and disconnect the heater water hose from the No. 1 air conditioning accessory assembly.
      GTY880621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on an engine lifter.
      NOTE:
      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle level.
      • 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 3 bolts and nut and separate the engine mounting insulator sub-assembly RH from the engine mounting bracket RH.
      GTY880629Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 bolts and engine mounting stay LH from the engine mounting insulator sub-assembly LH.
      GTY880624Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 bolts and separate the engine mounting insulator sub-assembly LH from the hybrid vehicle transaxle assembly.
      GTY880623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. GTY937637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Remove the 2 bolts (A), 2 bolts (B) and 4 nuts and front bumper extension sub-assembly RH and front bumper extension sub-assembly LH from the front frame assembly and vehicle body.

    6. Remove the 4 bolts (C) and 2 bolts (D) and front suspension member brace rear RH and front suspension member brace rear LH from the front frame assembly and vehicle body.
    7. 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.
  39. REMOVE FUEL DELIVERY GUARD 
    1. Remove the bolt and fuel delivery guard from the engine mounting bracket RH.
      GTY880619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. INSTALL ENGINE HANGERS 
    1. Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.
      GTY902431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

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

      HINT: 

      No. 1 Engine Hanger 12281-25030
      No. 2 Engine Hanger 12282-25010
      Bolt 90105-A0354 or
      91552-F1040
    2. Using an engine sling device and engine lift, 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.
  41. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the flywheel housing under cover from the cylinder block sub-assembly.
      GTY753666Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE STEERING GEAR HEAT INSULATOR 

    Refer to PROCEDURE - Step 9

  43. REMOVE ENGINE WIRE 
    1. Disconnect all clamps and connectors and remove the engine wire from the engine assembly with transaxle.
  44. REMOVE HV AIR CONDITIONING WIRE 
    1. Disengage the 2 clamps.
      GTY880617Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, slide the green-colored lock of the connector as shown in the illustration to release it and disconnect the connector.
      GTY743434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Green-colored Lock
      Slide
      WARNING:

      Make sure to wear insulated gloves.

      NOTE:

      Insulate the disconnected terminals and connector with insulating tape.

    3. Remove the 2 bolts.
      GTY880618Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disengage the guide to remove the HV air conditioning wire from the hybrid vehicle transaxle assembly.
  45. REMOVE HEATER WATER HOSE (w/ Exhaust Heat Recirculation System) 
    1. Disengage the clamp to disconnect the heater water hose.
      GTY902966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and remove the heater water hose from the flow shutting valve (water by-pass hose assembly).
      GTY881015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE STARTER HOLE INSULATOR 

    Refer to PROCEDURE - Step 10

  47. REMOVE FLYWHEEL HOUSING SIDE COVER 

    Refer to PROCEDURE - Step 11

  48. REMOVE FRONT FRAME ASSEMBLY 

    Refer to PROCEDURE - Step 7

  49. REMOVE FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Remove the bolt and front engine mounting insulator from the front engine mounting bracket.
      GTY880705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE REAR ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Remove the bolt and wire harness clamp from the rear engine mounting insulator.
      GTY1104464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and rear engine mounting insulator from the rear engine mounting bracket.
      GTY1104465Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 17

  52. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY 

    Refer to PROCEDURE - Step 2

  53. REMOVE FLYWHEEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  54. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 

    Refer to PROCEDURE - Step 4

  55. INSTALL ENGINE ASSEMBLY TO ENGINE STAND 
    1. Install the engine assembly to an engine stand.
  56. REMOVE ENGINE HANGERS 
    1. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and engine mounting bracket RH.
  57. DISCONNECT INVERTER RESERVE TANK ASSEMBLY 
    1. Remove the 2 bolts.
      GTY848566Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Grommet
    2. Disengage the pin and disconnect the inverter reserve tank assembly.
  58. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

    1. Remove the bolt and No. 1 inverter reserve tank bracket.
      GTY880649Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps.
      GTY880650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt, nut and disconnect the radiator reserve tank assembly.
      GTY867430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    4. Remove the bolt and disconnect the No. 2 earth wire from the engine mounting insulator sub-assembly RH.
      GTY880652Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Remove the 2 bolts, nut and engine mounting insulator sub-assembly RH.
      GTY934878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
  59. REMOVE ENGINE MOUNTING SPACER 

    HINT: 

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

    1. GTY880647Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 2 bolts and engine mounting spacer from the vehicle body.

  60. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH 

    HINT: 

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly LH is necessary.

    1. Remove the 2 bolts, nut and engine mounting insulator sub-assembly LH.
      GTY890709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
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