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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Engine Mechanical >> Accessory Drive Belts >> Engine Mechanical System (2GR-FKS) - Service Information (1 Of 2) >> Engine Assembly >> Removal [12/2019 - 09/2020] >> Procedure

Removal [12/2019 - 09/2020]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the ignition 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 [12/2019 - 11/2023]

  2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 

    Refer to PROCEDURE - Step 1

  3. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PRECAUTION [12/2019 - 10/2022]

  4. 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 [12/2019 - 09/2020]

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

    Refer to PROCEDURE - Step 3

  7. REMOVE FRONT WHEELS 

    Refer to PROCEDURE - Step 1

  8. REMOVE FRONT WHEEL OPENING EXTENSION PAD LH 
    1. Remove the 4 screws and front wheel opening extension pad LH.
      GTY931499Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE FRONT WHEEL OPENING EXTENSION PAD RH 
    1. Remove the 4 screws and front wheel opening extension pad RH.
      GTY862340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE NO. 1 ENGINE UNDER COVER 
    1. Remove the 3 bolts, 2 clips, 8 screws and No. 1 engine under cover.
      GTY926393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
  11. REMOVE REAR ENGINE UNDER COVER LH 
    1. Remove the bolt, 3 clips, screw and rear engine under cover LH.
      GTY867768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw
  12. REMOVE REAR ENGINE UNDER COVER RH 
    1. GTY846650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw

      Remove the bolt, 3 clips, screw and rear engine under cover RH.

  13. REMOVE FRONT FLOOR COVER LH 
    1. GTY876875Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw

      Remove the 4 bolts, 3 clips, 5 screws and front floor cover LH.

  14. REMOVE FRONT FLOOR COVER RH 
    1. GTY872265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Screw

      Remove the 5 bolts, 3 clips, 3 screws and front floor cover RH.

  15. REMOVE FRONT FENDER APRON SEAL LH 
    1. Remove the 2 bolts, clip and front fender apron seal LH from the vehicle body.
      GTY862337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE FRONT FENDER APRON SEAL RH 
    1. Remove the 2 bolts, clip and front fender apron seal RH from the vehicle body.
      GTY862338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE FRONT BUMPER COVER 

    Refer to REMOVAL [12/2019 - 09/2020]

  18. DRAIN ENGINE COOLANT 

    Refer to PROCEDURE - Step 1

  19. DRAIN ENGINE OIL 

    Refer to PROCEDURE - Step 2

  20. DRAIN AUTOMATIC TRANSAXLE FLUID (for 2WD) 

    Refer to PROCEDURE - Step 3

  21. DRAIN AUTOMATIC TRANSAXLE FLUID (for AWD) 

    Refer to PROCEDURE - Step 3

  22. DRAIN TRANSFER OIL (for AWD) 

    Refer to PROCEDURE - Step 1

  23. REMOVE V-BANK COVER SUB-ASSEMBLY 
    1. Hold the rear of the V-bank cover sub-assembly and raise it to disengage the 2 rear clips.
      GTY885423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Raise the V-bank cover sub-assembly to disengage the 2 front clips and remove the V-bank cover sub-assembly.
      NOTE:

      Attempting to disengage both front and rear clips at the same time may cause the V-bank cover sub-assembly to break.

  24. REMOVE INLET AIR CLEANER ASSEMBLY 
    1. Remove the 2 bolts and inlet air cleaner assembly.
      GTY862332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 
    1. Remove the vacuum hose bracket from the air cleaner hose.
      GTY875633Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 No. 1 Fuel Vapor Feed Hose
      *2 No. 2 Ventilation Hose
      *3 Vacuum Hose Bracket
    2. Disengage the 2 clamps to disconnect the No. 1 fuel vapor feed hose from the air cleaner hose.
    3. Slide the clip and disconnect the No. 2 ventilation hose from the air cleaner hose.
    4. Loosen the hose clamp.
      GTY931497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Disconnect the mass air flow meter sub-assembly connector.
      GTY873429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
    6. Disengage the 2 wire harness clamps.
    7. Disconnect the vacuum hose from the air cleaner hose.
    8. Disengage the 3 pins and remove the air cleaner assembly with air cleaner hose.
      NOTE:

      Make sure the air cleaner support remains attached to the vehicle body.

  26. REMOVE ECM 

    Refer to PROCEDURE - Step 5

  27. DISCONNECT ENGINE ROOM MAIN WIRE 
    1. Remove the nut and disconnect the engine wire with engine room main wire from the positive (+) battery terminal.
      GTY766939Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT ENGINE WIRE 
    1. Remove the nut and disconnect the engine wire from the negative (-) battery terminal.
      GTY878028Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A w/ Stop and Start System
      *B w/o Stop and Start System
  29. REMOVE BATTERY 

    Refer to PROCEDURE - Step 2

  30. REMOVE BATTERY CLAMP SUB-ASSEMBLY 
    1. Disengage the 5 clamps from the battery clamp sub-assembly.
      GTY862333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and battery clamp sub-assembly.
  31. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 
    1. While disengaging the clip (A) as shown in the illustration, disconnect the transmission control cable assembly from the transmission control shaft lever together with the clip (A).
      GTY839515Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Clip (A)
      *b 45° to 60°
      *c Clip (B)
    2. Remove the clip (B) and disconnect the transmission control cable assembly from the transmission control cable bracket.
  32. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Slide the clip and disconnect the No. 1 fuel vapor feed hose from the purge valve (purge VSV).
      GTY862331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. DISCONNECT CONNECTOR TO CHECK VALVE HOSE 
    1. Slide the clip and disconnect the connector to check valve hose from the brake booster assembly.
      GTY931503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. DISCONNECT NO. 2 RADIATOR HOSE 
    1. Slide the clip and disconnect the No. 2 radiator hose from the water inlet.
      GTY862358Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. SEPARATE RADIATOR HOSE SUB-ASSEMBLY 
    1. Slide the clip and disconnect the No. 4 water by-pass hose from the radiator hose sub-assembly.
      GTY862356Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slide the clip and disconnect the radiator hose sub-assembly from the water outlet.
    3. Disengage the clamp.
    4. Remove the 2 bolts and separate the radiator hose sub-assembly from the engine assembly.
  36. DISCONNECT INLET HEATER WATER HOSE B 
    1. GTY862357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the 2 clamps.

    2. Slide the clip and disconnect the inlet heater water hose B from the water outlet.
  37. DISCONNECT WATER BY-PASS HOSE ASSEMBLY 
    1. w/ Heater Water Pump
      GTY863671Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Pull out
      Pull off
      1. Pull out the retainer to disengage the lock claws and pull off the water by-pass hose assembly from the heater water pump assembly.
      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 heater water pump assembly and water by-pass hose assembly connector with plastic bags to prevent damage and contamination.
    2. w/o Heater Water Pump
      GTY859177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Retainer
      Pull out
      Pull off
      1. Pull out the retainer to disengage the lock claws and pull off the water by-pass hose assembly from the water hose sub-assembly.
      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 water hose sub-assembly and water by-pass hose assembly connector with plastic bags to prevent damage and contamination.
  38. DISCONNECT NO. 1 FUEL HOSE 
    1. Disengage the 2 claws to remove the No. 2 fuel pipe clamp.
      GTY862359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the No. 1 fuel pipe clamp from the fuel tube connector.
      GTY878177Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the No. 1 fuel hose (for Port Injection).
      1. Disconnect the No. 1 fuel hose from the fuel pipe.

        Refer to PRECAUTION [12/2019 - 10/2022]

        GTY878183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Disconnect the No. 1 fuel hose (for Direct Injection).
      1. Disconnect the No. 1 fuel hose from the fuel pipe.

        Refer to PRECAUTION [12/2019 - 10/2022]

        GTY878181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  40. DISCONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  41. DISCONNECT ENGINE WIRE 

    HINT: 

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

    1. GTY934974Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the No. 1 relay block cover from the engine room relay block and junction block assembly.

    2. Remove the nut from the engine room relay block and junction block assembly.
      GTY878178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the 5 connectors from the engine room relay block and junction block assembly.
    4. Disengage the 2 clamps.
    5. Using a screwdriver, disengage the claw and disconnect the engine wire from the engine room relay block and junction block assembly.
    6. Remove the bolt.
      GTY934976Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Disengage the 2 clamps and disconnect the engine wire from the vehicle body.
    8. Disengage the 3 clamps.
      GTY878187Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. DISCONNECT NO. 3 TRANSMISSION OIL COOLER HOSE 
    1. Slide the clip and disconnect the No. 3 transmission oil cooler hose from the No. 1 oil cooler tube sub-assembly without hose.
      GTY878186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp.
  43. DISCONNECT OUTLET NO. 1 OIL COOLER HOSE 
    1. Slide the clip and disconnect the outlet No. 1 oil cooler hose from the oil cooler union sub-assembly.
      GTY885443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 5

  45. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) 

    Refer to REMOVAL [12/2019 - 10/2022]

  46. REMOVE EXHAUST MANIFOLD 

    Refer to REMOVAL [12/2019 - 10/2022]

  47. REMOVE FRONT DRIVE SHAFT ASSEMBLY 

    Refer to REMOVAL [12/2019 - 10/2022]

  48. REMOVE FLYWHEEL HOUSING UNDER COVER 
    1. Remove the 2 bolts and flywheel housing under cover.
      GTY686606Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for 2WD) 

    Refer to PROCEDURE - Step 2

  50. REMOVE DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for AWD) 

    Refer to PROCEDURE - Step 2

  51. REMOVE FRONT BUMPER LOWER ABSORBER 

    Refer to PROCEDURE - Step 26

  52. REMOVE NO. 2 FRONT BUMPER REINFORCEMENT 

    Refer to PROCEDURE - Step 28

  53. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set 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.
      • To prevent the No. 2 oil pan sub-assembly from deforming, do not place any attachments under the No. 2 oil pan sub-assembly of the engine assembly with transaxle.
    2. GTY878174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.

    3. GTY878200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the 3 bolts and nut and separate the engine mounting insulator sub-assembly RH from the front No. 1 engine mounting bracket LH.

    4. GTY878199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the bolt and nut and separate the engine mounting insulator LH from the engine mounting bracket sub-assembly LH.

    5. GTY879849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

      Remove the 2 bolts (A), 2 bolts (B), 4 nuts, 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), 2 bolts (D), 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.
  54. DISCONNECT VACUUM HOSE 
  55. REMOVE STARTER ASSEMBLY 
  56. REMOVE BREATHER PLUG HOSE 
  57. REMOVE TRANSMISSION BREATHER CLAMP 
  58. DISCONNECT WATER BY-PASS HOSE ASSEMBLY 
  59. DISCONNECT HOSE CLAMP 
  60. REMOVE ENGINE WIRE 
    1. Disconnect all clamps and connectors and remove the engine wire from the engine assembly with transaxle.
  61. INSTALL ENGINE HANGERS 
    1. Install the No. 1 engine hanger and No. 2 engine hanger with the 4 bolts as shown in the illustration.

      Torque: 33 N.m (337 kgf/cm, 24 ft.lbf) 

      HINT: 

      No. 1 Engine Hanger 12281-31121
      No. 2 Engine Hanger 12282-31100
      Bolt 90119-A0117
      GTY732836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1
      *B for Bank 2
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger
    2. Using an engine sling device and engine lifter, secure the engine assembly with transaxle.
      NOTE:
      • Adjust the angle of the sling device carefully to prevent damage or deformation to the engine hangers or engine assembly.
      • 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.
  62. REMOVE FRONT FRAME ASSEMBLY 
    1. GTY878202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the bolt and separate the front engine mounting insulator from the front engine mounting bracket.

    2. GTY934979Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Remove the bolt and separate the rear engine mounting insulator from the rear engine mounting bracket sub-assembly.

  63. REMOVE FRONT ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Remove the 3 nuts and front engine mounting insulator from the front frame assembly.
      GTY878201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE REAR ENGINE MOUNTING INSULATOR 

    HINT: 

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

    1. Remove the 4 nuts and rear engine mounting insulator from the front frame assembly.
      GTY878208Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE FRONT ENGINE MOUNTING BRACKET 
  66. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY 
  67. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  2

  68. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 

    See step  3

  69. INSTALL ENGINE ASSEMBLY TO ENGINE STAND 
    1. Install the engine assembly to an engine stand.
  70. REMOVE ENGINE HANGERS 
    1. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly and cylinder head LH.
  71. 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. GTY878207Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Disengage the 2 clamps.

    2. Remove the bolt, nut and separate the radiator reserve tank assembly.
    3. Remove the bolt and disconnect the No. 2 earth wire from the engine mounting insulator sub-assembly RH.
      GTY878184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the nut, 2 bolts and engine mounting insulator sub-assembly RH from the engine mounting spacer and vehicle body.
      GTY878206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. REMOVE ENGINE MOUNTING SPACER 

    HINT: 

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

    1. GTY934980Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  73. REMOVE ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH 

    HINT: 

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

    1. Remove the 4 bolts and engine mounting bracket sub-assembly LH from the vehicle body.
      GTY934978Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. REMOVE ENGINE MOUNTING INSULATOR LH 

    HINT: 

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

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