Toyota Highlander Hybrid 6 2005-06

Throttle Body

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Removal & Installation



2.4L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant into a suitable container.
  4.  
  5. Remove the air cleaner cap with air cleaner hose.
  6.  
  7. Disconnect the accelerator control cable from the throttle body.
  8.  
  9. Detach the Throttle Position (TP) sensor connector and Idle Speed Control (ISC) valve connector.
  10.  
  11. Disconnect the vacuum hose from the throttle body.
  12.  
  13. Disconnect 2 water by-pass hoses.

    Click image to see an enlarged view

    Fig. Disconnect the electrical connectors, vacuum lines and water hoses from the throttle body

  14.  
  15. Remove 3 bolts and throttle body from intake manifold.

    Click image to see an enlarged view

    Fig. The throttle body is secured to the intake manifold with 3 bolts

  16.  
  17. Remove the throttle body gasket and discard it.
  18.  
  19. If necessary, remove the 2 retaining screws and the TP sensor.
  20.  
  21. If necessary, remove the 3 retaining screws and the ISC valve.

    Click image to see an enlarged view

    Fig. Remove the 3 retaining screws and the Idle Speed Control (ISC) valve

  22.  

To install:

  1. If removed, install the ISC valve with a new gasket and secure with the retaining screws.
  2.  
  3. If removed, install the TP sensor, as follows:
    1. Make sure the throttle valve is fully closed.
    2.  
    3. Rotate the sensor 45° in the left direction to the throttle valve fully closed position, and insert the TP sensor to the throttle body.
    4.  
    5. Rotate the sensor 45° in the right direction and install the 2 retaining screws.

      Click image to see an enlarged view

      Fig. Installing the Throttle Position (TP) sensor

    6.  

  4.  
  5. Position a new throttle body gasket on the intake manifold, as shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Position a new throttle body gasket on the intake manifold

  6.  
  7. Install the throttle body and secure with the 3 bolts. Tighten to 22 ft. lbs. (30 Nm).
  8.  
  9. Connect the 2 water by-pass hoses to the throttle body.
  10.  
  11. Connect the vacuum hose to the throttle body.
  12.  
  13. Attach the ISC valve and TP sensor connectors.
  14.  
  15. Connect the accelerator control cable to the throttle body.
  16.  
  17. Install the air cleaner hose and cap.
  18.  
  19. Fill the engine with the proper type and amount of coolant.
  20.  
  21. Connect the negative battery cable, then start the engine and check for coolant leaks. Check the coolant level and add more coolant if necessary.
  22.  

3.3L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the coolant into a suitable container.
  4.  
  5. Remove the 2 nuts and the front suspension upper center brace
  6.  
  7. Remove v-bank cover, as follows:
    1. Using a socket hexagon wrench 5, remove the 3 nuts.
    2.  
    3. Remove the v-bank cover.

      Click image to see an enlarged view

      Fig. V-bank cover mounting

    4.  

  8.  
  9. Remove the air cleaner inlet assembly.
  10.  
  11. Remove the air cleaner assembly.
    NOTE
    Note that the sub-steps for intake air resonator removal and installation correspond with the letters in the accompanying illustration.

  12.  
  13. Remove the intake air resonator, as follows:
    1. Remove the ventilation hose no. 2.
    2.  
    3. Remove the fuel vapor feed hose from the 2 hose clamps.
    4.  
    5. Loosen the air cleaner hose clamp bolt, and then remove the intake air resonator.

      Click image to see an enlarged view

      Fig. Intake air resonator removal and installation

    6.  

  14.  
  15. Remove the throttle body assembly, as follows:
    1. Disconnect the throttle control motor and Throttle Position (TP) sensor connector.
    2.  
    3. Disconnect the water by-pass hose no. 2.
    4.  
    5. Disconnect the water by-pass hose no. 3.
    6.  
    7. Remove the 2 bolts, 2 nuts and throttle body.
    8.  
    9. Remove and discard the gasket.

      Click image to see an enlarged view

      Fig. Detach the throttle control motor and TP sensor connector (A), then remove the no. 2 (b) and no. 3 (c) water by-pass hoses

    10.  

  16.  

To install:

  1. Install throttle body assembly, as follows:
    1. Install a new gasket to the intake air connector.
    2.  
    3. Install the throttle body with the 2 bolts and 2 nuts and tighten to 8 ft. lbs. (11 Nm).
    4.  
    5. Connect the water by-pass hoses.
    6.  
    7. Attach the throttle control motor and TP sensor connector.
    8.  

  2.  
  3. Install the intake air resonator
  4.  
  5. Install the air cleaner assembly.
  6.  
  7. Install the air cleaner inlet assembly.
  8.  
  9. Check the vacuum hose connections.
  10.  
  11. Fill the engine with the proper type and amount of coolant.
  12.  
  13. Check for coolant leaks.
    1. Install v-bank cover, as follows:
    2.  
    3. Fit the 2 retainers and install the v-bank cover.
    4.  
    5. Using a socket hexagon wrench 5, tighten the 3 nuts to 70 inch lbs. (8 Nm).
    6.  

  14.  
  15. Install front suspension upper center brace. Tighten the 2 nuts to 59 ft. lbs. (80 Nm).
  16.  
  17. Connect the negative battery cable, then start the engine and check for coolant leaks. Check the coolant level and add more coolant if necessary.
  18.  

 
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