Toyota Highlander 6 2001-06

Removal & Installation

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3.3L Engine



  1. Drain the coolant into a suitable container.
  2.  
  3. Disconnect the radiator outlet hose.
  4.  
  5. Remove the bolt and the water inlet pipe.
  6.  
  7. Remove the 3 bolts and water inlet.
  8.  
  9. Remove the thermostat.
  10.  
  11. Remove and discard the gasket, and thoroughly clean the gasket mating surfaces.
  12.  

To install:

  1. Position a new gasket to the thermostat.
  2.  
  3. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat into the water inlet housing.
    NOTE
    The jiggle valve can be placed within 15° of either side of the described position.



    Click image to see an enlarged view

    Fig. The jiggle valve may be set within 15° on either side of the described position

  4.  
  5. Install the water inlet and tighten the bolts to 71 inch lbs. (8 Nm).
  6.  
  7. Install the water inlet pipe, as follows:
    1. Install a new O-ring to the inlet pipe.
    2.  
    3. Apply soapy water to the O-ring.
    4.  
    5. Connect the inlet pipe to the water inlet.
    6.  
    7. Install the bolt holding the inlet pipe to the cylinder head and tighten to 15 ft. lbs. (20 Nm).
    8.  

  8.  
  9. Connect the radiator outlet hose.
  10.  
  11. Fill the engine with the proper type and amount of engine coolant.
  12.  
  13. Start the engine and check for coolant leaks. Recheck the coolant level and add, as necessary.
  14.  

Hybrid



  1. Disconnect the negative battery cable.
  2.  
  3. Using a clip remover, remove the engine side cover.

    Click image to see an enlarged view

    Fig. Use a clip removal tool to remove the engine side cover

  4.  
  5. Drain the hybrid vehicle coolant.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Disconnect the negative battery cable.
  10.  
  11. Remove the service plug grip.
  12.  
  13. Remove front upper center suspension brace subassembly, as follows:
    1. Remove the 4 nuts and front suspension brace subassembly.
    2.  
    3. Install the 4 shock absorber nuts and tighten to 59 ft .lbs. (80 Nm).

      Click image to see an enlarged view

      Fig. Remove front upper center suspension brace subassembly

    4.  

  14.  
  15. Remove the air cleaner cap w/ inlet, as follows:
    1. Remove the 2 bolts, 4 clamps and air cleaner cap w/ inlet.
    2.  
    3. Remove the air cleaner filter element from the air cleaner case.
    4.  

  16.  
  17. Remove air cleaner w/resonator.
  18.  
  19. Remove inverter bracket no.5.
  20.  
  21. Remove power steering ECU, as outlined in the Suspension and Steering Section.
  22.  
  23. Disconnect the circuit breaker sensor no.1.
  24.  
  25. Disconnect engine room wire no.2.
  26.  
  27. Remove the inverter reserve tank subassembly.
  28.  
  29. Disconnect water hose.
  30.  
  31. Disconnect the power steering ECU bracket.
  32.  
  33. Remove the inverter cover.
  34.  
  35. Verify voltage of w/converter inverter assembly is 0 v.
  36.  
  37. Separate engine wire no.4.
  38.  
  39. Disconnect high voltage cable from the front motor.
  40.  
  41. Disconnect the MG ECU connector.
  42.  
  43. Disconnect the no.3 wire frame.
  44.  
  45. Install the inverter cover.
  46.  
  47. Separate engine room relay block assembly
  48.  
  49. Remove the inverter bracket no.4.
  50.  
  51. Remove w/converter inverter assembly.
  52.  
  53. Remove the water inlet pipe, as follows:
    1. Remove the bolt and the water inlet pipe.
    2.  
    3. Remove the o-ring from the water inlet pipe.

      Click image to see an enlarged view

      Fig. Remove the water inlet pip

    4.  

  54.  
  55. Remove the water inlet, as follows:
    1. Disconnect the wire harness clamp.
    2.  
    3. Remove the 3 nuts and the water inlet.

      Click image to see an enlarged view

      Fig. Disconnect the wire harness clamp, remove the 3 nuts, then remove the water inlet

    4.  

  56.  
  57. Remove the thermostat, as follows:
    1. Remove the thermostat.
    2.  
    3. Remove the gasket from the thermostat and discard. Thoroughly clean the gasket mating surfaces.

      Click image to see an enlarged view

      Fig. Exploded view of the components you need to remove to access the thermostat (1 of 3)-all models



      Click image to see an enlarged view

      Fig. Exploded view of the components you need to remove to access the thermostat (2 of 3)-2WD models



      Click image to see an enlarged view

      Fig. Exploded view of the components you need to remove to access the thermostat (3 of 3)-4WD models



      Click image to see an enlarged view

      Fig. Exploded view of the thermostat and related components

    4.  

  58.  

To install:

  1. Install thermostat:
    1. Install a new gasket to the thermostat.
    2.  
    3. Align the jiggle valve of the thermostat and water inlet, and insert the thermostat in the water inlet housing.
      NOTE
      The jiggle valve should be set within +-15° from the prescribed position.



      Click image to see an enlarged view

      Fig. Proper installed position of the jiggle valve

    4.  

  2.  
  3. Install water inlet. Tighten the 3 retaining nuts to 71 inch lbs. (8 Nm).
    1. Install the water inlet pipe:
    2.  
    3. Install a new o-ring to the water inlet pipe.
    4.  
    5. Apply soapy water to the o-ring.
    6.  
    7. Connect the water inlet pipe to the water inlet.
    8.  
    9. Install the bolt which is used to fix the water inlet pipe to the cylinder head with the bolt. Tighten to 15 ft. lbs. (20 Nm).
    10.  

  4.  
  5. Install w/converter inverter assembly.
  6.  
  7. Install inverter bracket no.4.
  8.  
  9. Install engine compartment relay block assembly.
  10.  
  11. Remove inverter cover.
  12.  
  13. Connect no.3 wire frame.
  14.  
  15. Connect MG ECU connector.
  16.  
  17. Connect high voltage cable of front motor
  18.  
  19. Connect engine wire no.4.
  20.  
  21. Check high voltage cable connection.
  22.  
  23. Install inverter cover.
  24.  
  25. Install the power steering ECU bracket.
  26.  
  27. Connect the water hose.
  28.  
  29. Install inverter reserve tank subassembly.
  30.  
  31. Connect engine room wire no.2.
  32.  
  33. Connect circuit breaker sensor no.1.
  34.  
  35. Install the power steering ECU assembly.
  36.  
  37. Install the inverter bracket no.5.
  38.  
  39. Install air cleaner w/resonator.
  40.  
  41. Install air cleaner cap w/inlet.
  42.  
  43. Install the front suspension upper center brace subassembly.
  44.  
  45. Install service plug grip.
  46.  
  47. Connect the negative battery cable.
  48.  
  49. Add hybrid vehicle coolant.
  50.  
  51. Add engine coolant.
  52.  
  53. Check hybrid vehicle coolant leaks
  54.  
  55. Check for engine coolant leaks
  56.  
  57. Install engine side cover.
  58.  
  59. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  60.  

 
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