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Home >> Toyota Truck >> 2011 >> Highlander 4WD V6-3.5L (2GR-FXE) Hybrid >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine Assembly >> Removal

Removal





2GR-FXE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL

CAUTION:
As the engine assembly with transaxle is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

1. REMOVE COOL AIR INTAKE DUCT SEAL Removal

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM Service and Repair

3. DISCHARGE FUEL SYSTEM PRESSURE

Service Precautions

4. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

5. REMOVE DECK BOARD ASSEMBLY Removal

6. REMOVE BATTERY SERVICE HOLE COVER ASSEMBLY Removal

7. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

8. REMOVE REAR DOOR SCUFF PLATE LH Removal

9. REMOVE RECLINING HINGE COVER LH Removal

10. REMOVE SERVICE PLUG GRIP Removal

11. REMOVE FRONT WHEEL

12. DISCONNECT FRONT FENDER LINER RH Removal

13. DISCONNECT FRONT FENDER LINER LH

HINT
Perform the same procedure as for the RH side.

14. REMOVE NO. 1 ENGINE UNDER COVER Coolant (for Engine)

15. REMOVE NO. 2 ENGINE UNDER COVER

(a) Remove the 4 bolts, clip and No. 2 engine under cover.





16. REMOVE FRONT FLOOR COVER LH Removal

17. REMOVE FRONT FENDER APRON SEAL RH Removal

18. DRAIN ENGINE OIL Replacement

19. DRAIN ENGINE COOLANT Coolant (for Engine)

20. DRAIN COOLANT (for Inverter) Coolant (for Inverter)

21. DRAIN HYBRID TRANSAXLE FLUID P313 Hybrid Transaxle

22. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH Removal

23. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH Removal

24. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Removal

25. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Removal

26. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY Removal

27. REMOVE V-BANK COVER SUB-ASSEMBLY

(a) Hold the front of the cover and raise it to detach the 2 retainers on the front of the cover. Continue to raise the cover to detach the 2 retainers on the rear of the cover and remove the cover.





NOTICE:
Attempting to detach both the front and rear retainers at the same time may cause the cover to break.

28. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY Removal

29. REMOVE NO. 2 AIR CLEANER INLET Removal

30. REMOVE NO. 1 AIR CLEANER INLET Removal

31. REMOVE AIR CLEANER ASSEMBLY WITH HOSE Removal

32. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY Removal

33. REMOVE NO. 3 INVERTER BRACKET Removal

34. REMOVE RADIATOR RESERVOIR Removal

35. DISCONNECT NO. 1 RADIATOR HOSE Removal

36. DISCONNECT NO. 2 RADIATOR HOSE Removal

37. REMOVE RADIATOR GRILLE Removal

38. REMOVE FRONT BUMPER COVER Removal

39. REMOVE LOW PITCHED HORN ASSEMBLY Removal

40. REMOVE HIGH PITCHED HORN ASSEMBLY Removal

41. REMOVE HOOD LOCK ASSEMBLY (w/o Engine Hood Courtesy Switch) Removal

42. REMOVE HOOD LOCK ASSEMBLY (w/ Engine Hood Courtesy Switch) Removal

43. REMOVE UPPER RADIATOR SUPPORT SUB-ASSEMBLY Removal

44. REMOVE NO. 2 RADIATOR ASSEMBLY Removal

45. REMOVE INVERTER RESERVE TANK ASSEMBLY Removal

46. REMOVE NO. 1 INVERTER RESERVE TANK BRACKET Removal

47. REMOVE INVERTER TERMINAL COVER Removal

48. CHECK TERMINAL VOLTAGE Removal

49. DISCONNECT NO. 4 ENGINE WIRE Removal

50. DISCONNECT HIGH VOLTAGE CABLE OF FRONT MOTOR Removal

51. DISCONNECT NO. 3 WIRE FRAME Removal

52. INSTALL INVERTER TERMINAL COVER Removal

53. DISCONNECT NO. 3 ENGINE ROOM RELAY BLOCK Removal

54. DISCONNECT MG ECU CONNECTOR Removal

55. DISCONNECT WATER HOSE Removal

56. DISCONNECT NO. 2 ENGINE ROOM WIRE Removal

57. REMOVE NO. 4 INVERTER BRACKET Removal

58. REMOVE INVERTER WITH CONVERTER ASSEMBLY Removal

59. REMOVE INVERTER TRAY BRACKET SUB-ASSEMBLY

(a) Detach the clamp and disconnect the water by-pass hose.

(b) Remove the 5 bolts and inverter tray bracket sub-assembly.





60. DISCONNECT NO. 1 MOTOR COOLING HOSE

(a) Disconnect the No. 1 motor cooling hose.





61. DISCONNECT NO. 3 MOTOR COOLING HOSE

(a) Disconnect the No. 3 motor cooling hose.





62. REMOVE NO. 1 RADIATOR HOSE

(a) Disconnect the No. 1 radiator hose from the radiator pipe clamp.





(b) Remove the No. 1 radiator hose.

63. REMOVE NO. 2 RADIATOR HOSE





64. DISCONNECT INLET HEATER WATER HOSE





65. DISCONNECT OUTLET HEATER WATER HOSE





66. DISCONNECT PURGE LINE HOSE





67. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Removal

68. DISCONNECT BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY Removal

69. REMOVE RESERVOIR BRACKET Removal

70. REMOVE NO. 2 ENGINE MOUNTING STAY RH Removal

71. REMOVE ENGINE MOVING CONTROL ROD

(a) Remove the 4 bolts and engine moving control rod with the engine mounting control bracket.





72. DISCONNECT ENGINE WIRE

(a) Push in the lock on the lever, raise the lever and disconnect the ECM connector.

NOTICE:
After disconnecting the connector, make sure that dirt, water or other foreign matter does not contact the connecting part of the connector.





(b) Detach the wire harness clamp.

(c) Remove the relay block cover.

(d) Disconnect the 3 connectors.





(e) Detach the 6 clamps.





(f) Remove the bolt and disconnect the engine wire.

(g) Remove the bolt and disconnect the ground wire from the hybrid vehicle transaxle assembly.





(h) Remove the 2 bolts and disconnect the ground wire.





73. DISCONNECT SUCTION HOSE SUB-ASSEMBLY Removal

74. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY Removal

75. DISCONNECT FUEL MAIN TUBE

(a) Disconnect the fuel main tube Service Precautions.





76. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY Removal

77. REMOVE FRONT EXHAUST PIPE ASSEMBLY Removal

78. SECURE STEERING WHEEL Removal

79. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY Removal

80. REMOVE FRONT AXLE SHAFT NUT LH Removal

81. REMOVE FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

82. SEPARATE FRONT SPEED SENSOR LH Removal

83. SEPARATE FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

84. SEPARATE TIE ROD ASSEMBLY LH Removal

85. SEPARATE TIE ROD ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

86. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH Removal

87. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

88. SEPARATE FRONT LOWER SUSPENSION ARM LH Removal

89. SEPARATE FRONT LOWER SUSPENSION ARM RH

HINT
Perform the same procedure as for the LH side.

90. SEPARATE FRONT DRIVE SHAFT ASSEMBLY LH Removal

91. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH Removal

92. REMOVE FRONT DRIVE SHAFT HOLE SNAP RING Disassembly

93. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

94. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH Removal

95. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET

(a) Remove the 2 nuts and No. 1 exhaust pipe support bracket.





96. REMOVE FLYWHEEL HOUSING UNDER COVER

(a) Remove the 2 bolts and flywheel housing under cover.





97. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set an engine lifter in place.





NOTICE:
* Place wooden blocks or plate lift attachments so that the engine is level.
* With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
* Never install attachments to the oil pan of the engine assembly or transaxle as doing so may deform the oil pan.

(b) Remove the 6 bolts, 2 nuts and frame side rail plate RH and LH.





(c) Remove the 6 bolts, 2 nuts and front suspension member rear brace RH and LH.

(d) Operate the engine lifter and remove the engine assembly from the vehicle.

NOTICE:
* Make sure that the engine is clear of all wiring and hoses.
* While lowering the engine from the vehicle, do not allow it to contact the vehicle.

98. REMOVE INTAKE AIR SURGE TANK ASSEMBLY Removal

99. REMOVE NO. 2 EGR PIPE Removal

100. REMOVE EGR COOLER ASSEMBLY Removal

101. REMOVE MANIFOLD STAY Removal

102. REMOVE NO. 1 EGR PIPE Removal

103. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH Removal

104. REMOVE EXHAUST MANIFOLD TO HEAD GASKET Removal

105. REMOVE NO. 2 MANIFOLD STAY Removal

106. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE Removal

107. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Removal

108. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH Removal

109. REMOVE EXHAUST MANIFOLD TO HEAD GASKET LH Removal

110. SEPARATE FRONT FRAME ASSEMBLY

(a) Disconnect the wire harness.





(b) Remove the bolt and wire harness bracket.

(c) Install a No. 1 and No. 2 engine hanger with 4 bolts.





Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)

Text in Illustration





HINT






(d) Attach a sling device to the engine hangers and a chain block.

(e) Detach the 2 clamps and disconnect the engine wire from the front frame assembly.





(f) Remove the nut and engine mounting insulator RH.





(g) Remove the 2 hole plugs.





(h) Remove the 3 nuts and engine mounting insulator LH.

(i) Remove the bolt and disconnect the front engine mounting insulator.





(j) Remove the 2 bolts and disconnect the rear engine mounting insulator.





NOTICE:
Do not remove the rear engine mounting insulator assembly through bolts. Doing so makes it difficult to install the rear engine mounting insulator assembly.

(k) Remove the front frame assembly.

NOTICE:
Do not damage any engine or transaxle components.

HINT
Raise the engine with hybrid transaxle assembly while keeping it level.

111. REMOVE HYBRID VEHICLE TRANSAXLE ASSEMBLY

Removal

112. FIX ENGINE ASSEMBLY

(a) Using wooden blocks or plate lift attachments, set the engine on a flat surface.

NOTICE:
* Place wooden blocks or plate lift attachments so that the engine is level.
* Never install attachments to the oil pan of the engine assembly or transaxle as doing so may deform the oil pan.
* Perform this step while supporting the engine assembly using a sling device and chain block.

113. REMOVE RADIATOR PIPE CLAMP

(a) Remove the bolt and radiator pipe clamp.





114. REMOVE TRANSMISSION INPUT DAMPER ASSEMBLY Removal

115. REMOVE FLYWHEEL SUB-ASSEMBLY Removal

116. INSTALL ENGINE TO ENGINE STAND

(a) Install the engine to an engine stand with the bolts.

NOTICE:
* Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.
* With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

(b) Remove the 4 bolts and 2 engine hangers.

117. REMOVE FRONT ENGINE MOUNTING INSULATOR

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





(a) Remove the hole plug.

(b) Remove the 3 nuts and front engine mounting insulator.

118. REMOVE REAR ENGINE MOUNTING INSULATOR ASSEMBLY

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





(a) Remove the 2 nuts and rear engine mounting insulator assembly.

NOTICE:
Do not remove the rear engine mounting insulator assembly through bolts. Doing so makes it difficult to install the rear engine mounting insulator assembly.

119. REMOVE ENGINE MOUNTING INSULATOR RH

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





(a) Remove the 2 hole plugs.

(b) Remove the 3 nuts and engine mounting insulator RH.

120. REMOVE ENGINE MOUNTING INSULATOR LH

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





(a) Remove the bolt and dynamic damper from the hybrid vehicle transaxle assembly.

(b) Remove the nut and engine mounting insulator LH from the hybrid vehicle transaxle assembly.




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