Toyota Highlander Hybrid 6 2005-06

Engine

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Removal & Installation




NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

2.4L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Matchmark the hood position.
  4.  
  5. Remove or disconnect the following:

    Front wheels
     
    No.1 engine undercover
     
    Right and left fender splash shields
     
    Right fender apron seal
     
    Engine oil
     
    Coolant
     
    Transaxle fluid
     
    Transfer case oil
     
    Battery
     
    Air cleaner
     
    Radiator hoses
     
    Oil cooler hoses
     
    Upper engine stay
     
    Upper engine mount bracket
     
    Accessory drive belts
     
    Steering pump reservoir
     
    Steering pump hoses
     
    All cables and wires connected to the engine
     
    Exhaust pipe
     
    Front drive shaft
     
    Stabilizer links
     
    Left and right axle hub nuts
     
    Left and right speed sensors
     
    Left and right tie rods
     
    Left and right lower control arms
     
    Torque converter-to-drive plate bolts
     
    Intermediate steering shaft
     
    AC compressor
     

  6.  
  7. Attach a crane, remove the 6 side rail plate subassembly bolts (3 each side) and the front suspension member rear brace.
  8.  
  9. Lift the engine out of the vehicle.

    Click image to see an enlarged view

    Fig. Engine mounts and related parts-2.4L engine

  10.  
  11. Installation is the reverse of removal. Observe the following torques:

    Frame side plate bolts: Large 63 ft. lbs. (85 Nm); small 24 ft. lbs. (32 Nm)
     
    Suspension member rear brace: Large 63 ft. lbs. (85 Nm); small 24 ft. lbs. (32 Nm)
     
    Intermediate shaft bolt: 26 ft. lbs. (35 Nm)
     
    Torque converter bolts: 30 ft. lbs. (41 Nm)
     
    Lower control arms, bolts and nuts: 94 ft. lbs. (127 Nm)
     
    Tie rod nuts: 36 ft. lbs. (49 Nm)
     
    Speed sensors: 71 inch lbs. (8 Nm)
     
    Hub nuts: 217 ft. lbs. (294 Nm)
     
    Stabilizer link nuts: 55 ft. lbs. (74 Nm)
     
    Driveshaft nuts: 55 ft. lbs. (74 Nm)
     
    Engine mount bracket: 15 ft. lbs. (20 Nm)
     
    Engine mount stay: 47 ft. lbs. (64 Nm)
     

  12.  

Hybrid
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the coolant from the engine and hybrid assemblies.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the transfer case fluid, if equipped.
  8.  
  9. Drain the hybrid transaxle fluid.
  10.  
  11. Discharge the fuel system pressure.
  12.  
  13. Remove the service plug grip, found underneath the Battery Service cover on the rear seat. Wait 5 minutes to discharge the high voltage capacitor.
  14.  
  15. Remove or disconnect the following:

    Engine room side covers
     
    Front wheels
     
    Engine under cover assembly
     
    Left and right fender splash shields
     
    Left and right fender apron seals
     
    Wiper arms
     
    Cowl top ventilator louver
     
    Wiper linkage
     
    Cowl top panel outer sub-assembly
     
    Battery and battery tray
     
    Air intake assembly
     
    Inverter support bracket No. 5
     
    Power steering ECU assembly
     

  16.  
  17. Remove the inverter with converter assembly as follows:
    1. Disconnect circuit breaker sensor No. 1.
    2.  
    3. Disconnect engine room wire No. 2.
    4.  
    5. Remove the inverter reserve tank sub-assembly.
    6.  
    7. Disconnect the coolant hose.
    8.  
    9. Disconnect the power steering ECU bracket.
    10.  
    11. Remove the inverter cover.
    12.  
    13. Verify the voltage of w/ converter inverter assembly is 0 volts.
    14.  
    15. Disconnect engine wire No. 4.
    16.  
    17. Disconnect the high voltage cable of the front motor.
    18.  
    19. Disconnect the Motor Generator ECU connector.
    20.  
    21. Disconnect No. 3 wire frame.
    22.  
    23. Install the inverter cover.
    24.  
    25. Separate the engine room relay block assembly.
    26.  
    27. Remove the inverter bracket No. 4.
    28.  
    29. Remove the w/ converter inverter assembly.
    30.  

  18.  
  19. Remove or disconnect the following:

    Brake master cylinder reservoir sub-assembly
     
    Master cylinder reservoir bracket