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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 Unit >> Removal [10/2022 - 11/2023] >> Procedure

Removal [10/2022 - 11/2023]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE DRIVE SHAFT BEARING BRACKET 
    1. Remove the 3 bolts and drive shaft bearing bracket.
      GTY773125Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE COMPRESSOR WITH MOTOR ASSEMBLY 
    1. Remove the bolt and 2 nuts.
      GTY744326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts and compressor with motor assembly.
      GTY751975Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. Slide the clip and disconnect the No. 2 water by-pass pipe sub-assembly from the water by-pass outlet.
      GTY885403Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt and the No. 2 water by-pass pipe sub-assembly.
  4. REMOVE FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY) 
    1. w/ Exhaust Heat Recirculation System:
      1. Remove the bolt.
        GTY885398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Slide the clip and remove the flow shutting valve (water by-pass hose assembly) from the water by-pass outlet.
        GTY885388Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. w/o Exhaust Heat Recirculation System:
      1. Remove the bolt.
        GTY995266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Slide the clip and remove the flow shutting valve (water by-pass hose assembly) from the water by-pass outlet.
        GTY1104343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and water hose clamp bracket.
      GTY885395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Type A:
      1. Remove the 5 bolts and the No. 1 exhaust manifold heat insulator from the exhaust manifold (TWC: Front Catalyst).
        GTY757874Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Type B:
      1. Remove the 3 bolts and the No. 1 exhaust manifold heat insulator from the exhaust manifold (TWC: Front Catalyst).
        GTY1084829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE MANIFOLD STAY 

    Refer to PROCEDURE - Step 15

  7. REMOVE EXHAUST MANIFOLD (TWC: Front Catalyst) 
    1. Using a 12 mm deep socket wrench, remove the 7 nuts and remove the exhaust manifold (TWC: Front Catalyst) from the cylinder head sub-assembly.
      GTY773124Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.
      GTY761390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 6

  9. REMOVE THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 7

  10. REMOVE EGR COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  11. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  12. REMOVE EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 4

  13. REMOVE NO. 3 WATER BY-PASS PIPE 
    1. Using an 8 mm socket wrench, remove the bolt and disconnect the No. 3 water by-pass pipe from the intake manifold.
      GTY761383Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and remove the No. 3 water by-pass pipe from the water outlet.
  14. REMOVE NO. 2 WATER BY-PASS PIPE 
    1. Remove the bolt (A).
      GTY1002389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an 8 mm socket wrench, remove the 2 bolts (B) and No. 2 water by-pass pipe.
  15. REMOVE INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 10

  16. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 11

  17. DISCONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  18. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. Using an 8 mm socket wrench, remove the bolt.
      GTY948032Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.
  19. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 9

  20. REMOVE NO. 7 WATER BY-PASS HOSE 
    1. Slide the 2 clips and remove the No. 7 water by-pass hose.
      GTY773122Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE SENSOR WIRE 
    1. Disconnect the 3 connectors.
      GTY1001473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 3 clamps.
    3. Using an 8 mm socket wrench, remove the bolt and sensor wire from the water inlet with thermostat sub-assembly.
  22. REMOVE NO. 6 ENGINE WIRE 
    1. Disconnect the 4 connectors.
      GTY761380Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the 2 clamps.
    3. Remove the 2 nuts and No. 6 engine wire from the wire harness clamp bracket.
  23. REMOVE WIRE HARNESS CLAMP BRACKET 
    1. Using an 8 mm socket wrench, remove the 2 bolts and wire harness clamp bracket from the No. 1 ventilation case.
      GTY761514Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 11

  25. REMOVE NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 12

  26. REMOVE INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 13

  27. REMOVE NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 14

  28. REMOVE PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 15

  29. REMOVE FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 9

  30. REMOVE DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 10

  31. REMOVE IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  32. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Remove the engine oil level dipstick.
    2. Using an 8 mm socket wrench, remove the bolt and engine oil level dipstick guide from the camshaft housing sub-assembly.
      GTY756776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring from the engine oil level dipstick guide.
      GTY756777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the bolt and No. 3 exhaust manifold heat insulator from the cylinder block sub-assembly.
      GTY885396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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