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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 [12/2019 - 10/2021] >> Procedure

Removal [12/2019 - 10/2021]: 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. 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
    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. 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
  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 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 6 [09/2020 - ]

  9. REMOVE THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 7 [12/2019 - 09/2020] , or refer to PROCEDURE - Step 7 [09/2020 - ]

  10. REMOVE EGR COOLER ASSEMBLY 
    1. Slide the clip and disconnect the No. 4 water by-pass hose from the EGR cooler assembly.
      GTY837456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 3 Water By-pass Hose
      *2 No. 4 Water By-pass Hose
    2. Slide the clip and disconnect the No. 3 water by-pass hose from the EGR cooler assembly.
    3. Remove the 5 bolts, EGR cooler assembly, EGR cooler gasket and EGR valve gasket.
      GTY773123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE NO. 1 EGR PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  12. REMOVE NO. 4 WATER BY-PASS HOSE 
    1. Slide the clip and remove the No. 4 water by-pass hose from the EGR valve assembly.
      GTY823619Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE EGR VALVE ASSEMBLY 
    1. Slide the clip and disconnect the No. 8 water by-pass hose from the EGR valve assembly.
      GTY761385Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. For EGR Valve Bracket Connection Type:
      1. Using an 8 mm socket wrench, remove the bolt and disconnect the No. 1 fuel pipe sub-assembly from the EGR valve bracket.
        GTY761382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Using an 8 mm socket wrench, remove the bolt.
      3. Remove the EGR valve assembly vertically.
        GTY744292Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Pin
        *b Hole
    3. For Cylinder Head Cover Sub-assembly Connection Type:
      1. Using an 8 mm socket wrench, remove the bolt.
        GTY948034Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Remove the EGR valve assembly vertically.
        GTY947779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Pin
        *b Hole
    4. Using an 8 mm socket wrench, remove the bolt and EGR valve bracket.
      GTY760316Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. 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.
  15. REMOVE NO. 2 WATER BY-PASS PIPE 
    1. Remove the bolt (A).
      GTY768412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an 8 mm socket wrench, remove the 2 bolts (B) and No. 2 water by-pass pipe.
  16. REMOVE INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 9

  17. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 10

  18. DISCONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  19. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. For EGR Valve Bracket Connection Type:
      1. Using a 17 mm union nut wrench, loosen the 2 union nuts of the No. 1 fuel pipe sub-assembly.
        GTY766718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. For Cylinder Head Cover Sub-assembly Connection Type:
      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.
  20. REMOVE FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 9

  21. 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
  22. REMOVE SENSOR WIRE 
    1. Disconnect the 4 connectors.
      GTY761379Courtesy 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.
  23. 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.
  24. 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
  25. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 11

  26. REMOVE NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 12

  27. REMOVE INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 13

  28. REMOVE NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 14

  29. REMOVE PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 15

  30. REMOVE FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 9

  31. REMOVE DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 10

  32. REMOVE IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  33. 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
  34. 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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