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Home >> Toyota >> 2016 >> Highlander Hybrid Limited >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2GR-FXE) (Service Information) (Hybrid) >> Engine Unit >> Disassembly [02/2014 - 11/2016] >> Procedure

Disassembly [02/2014 - 11/2016]: Procedure

  1. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap sub-assembly and oil filler cap gasket.
  2. REMOVE SPARK PLUG 

    Refer to PROCEDURE - Step 3

  3. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug and oil pan drain plug gasket.
      GTY232260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 
    1. Remove the PCV valve (ventilation valve sub-assembly).
      GTY439178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE CAMSHAFT POSITION SENSOR (for Bank 1) 

    Refer to PROCEDURE - Step 2

  6. REMOVE CAMSHAFT POSITION SENSOR (for Bank 2) 

    Refer to PROCEDURE - Step 3

  7. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1) 

    Refer to PROCEDURE - Step 2

  8. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2) 

    Refer to PROCEDURE - Step 3

  9. REMOVE CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 2

  10. REMOVE NO. 1 OIL PIPE 
    1. Remove the 2 oil pipe unions, 3 gaskets and No. 1 oil pipe.
      GTY435443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Pipe Union
    2. Remove the oil control valve filter LH.
      NOTE:

      Do not touch the mesh when removing the oil control valve filter LH.

  11. REMOVE OIL PIPE 
    1. Remove the bolt.
      GTY450145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Oil Pipe Union
      *b Bolt
    2. Remove the 2 oil pipe unions, 3 gaskets and oil pipe.
    3. Remove the oil control valve filter RH.
      NOTE:

      Do not touch the mesh when removing the oil control valve filter RH.

  12. REMOVE TAPER SCREW PLUG 

    HINT: 

    Perform this operation only when a taper screw plug is installed.

    1. Remove the taper screw plug from the cylinder block sub-assembly.
      GTY451306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY 
    GTY450214Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    *A for Bank 1
    *B for Bank 2
    1. for Bank 1:
      1. Remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.
      2. Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.
    2. for Bank 2:

      HINT: 

      Perform this operation only when a cylinder block water drain cock sub-assembly is installed.

      1. Remove the cylinder block water drain cock sub-assembly from the cylinder block sub-assembly.
      2. Remove the cylinder block water drain cock plug from the cylinder block water drain cock sub-assembly.
  14. REMOVE OIL FILTER CAP ASSEMBLY 

    Refer to PROCEDURE - Step 2

  15. REMOVE CRANKSHAFT PULLEY 

    See step  2

  16. REMOVE OIL COOLER ASSEMBLY 
    1. Slide the clip and disconnect the water by-pass pipe sub-assembly from the water inlet.
      GTY427261Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Nut
    2. Remove the 2 nuts, water by-pass pipe sub-assembly and gasket.
    3. Remove the bolt and hose clamp.
      GTY452597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Hose Clamp
      Bolt
    4. Slide the 2 clips and remove the No. 4 water by-pass hose from the oil cooler assembly and water outlet.
    5. Remove the oil cooler union bolt, oil cooler assembly and O-ring.
      GTY447945Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE NO. 1 OIL COOLER BRACKET 
    1. Remove the 3 bolts, 3 nuts, oil cooler pipe with No. 1 oil cooler bracket and gasket.
      GTY437396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.
      GTY428126Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    3. Using an E8 "TORX" socket wrench, remove the 2 stud bolts from the No. 1 oil cooler bracket.
    4. Using an E7 "TORX" socket wrench, remove the stud bolt from the cylinder block sub-assembly.
  18. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Remove the engine oil level dipstick guide.
      GTY299596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring.
      GTY452297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH 
    1. Remove the 6 bolts and No. 1 front engine mounting bracket LH.
      GTY438378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Stud Bolt
    2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
  20. REMOVE WATER OUTLET 
    1. Remove the 2 bolts, 4 nuts and water outlet.
      GTY447197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Remove the 2 gaskets and O-ring.
      GTY295919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.
      GTY428926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Washer
    2. Remove the 3 gaskets.
      GTY429822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly LH and No. 2 cylinder head cover gasket.
      GTY454959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Washer
      *a Baffle Plate
      NOTE:

      The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly LH.

    2. Remove the 3 gaskets.
      GTY429821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE WATER INLET HOUSING 
    1. Remove the 2 nuts, water inlet and thermostat.
      GTY437278Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket.
    3. Remove the 2 stud bolts.
    4. Slide the clip and disconnect the No. 1 water by-pass hose from the water inlet housing.
    5. Remove the drain cock plug.
      GTY443736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Drain Cock
      Bolt
      Nut
    6. Remove the drain cock assembly.
    7. Remove the 2 bolts, nut and water inlet housing.
    8. Remove the O-ring and gasket.
      GTY355490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove the 16 bolts and 2 nuts.
      GTY440014Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and No. 2 oil pan sub-assembly. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.
      GTY145991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the contact surfaces of the oil pans.

    3. Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the oil pan sub-assembly.
  25. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.
      GTY442571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    2. Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the timing chain cover sub-assembly.
  26. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the oil pan sub-assembly.

      See step  38

    2. Using an E8 "TORX" socket wrench, remove the 4 stud bolts.
      GTY586513Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A Type A *B Type B
      *a Timing Chain Cover Sub-assembly Side *b Cylinder Block Sub-assembly Bottom Side
      *c Oil Pan Sub-assembly LH Side - -
  27. REMOVE NO. 1 OIL PAN BAFFLE PLATE 
    1. Remove the 7 bolts and No. 1 oil pan baffle plate.
      GTY146508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE REAR ENGINE OIL SEAL RETAINER 
    1. Remove the 6 bolts.
      GTY124017Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, pry out the rear engine oil seal retainer.
      GTY449342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      Pry
      NOTE:

      Be careful not to damage the rear engine oil seal retainer.

      HINT: 

      Tape the screwdriver tip before use.

  29. REMOVE REAR ENGINE OIL SEAL 
    1. Place the rear engine oil seal retainer on wooden blocks.
      GTY436341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      *b Wooden Block
    2. Using a screwdriver and hammer, tap out the rear engine oil seal.
      NOTE:

      Be careful not to damage the rear engine oil seal retainer.

      HINT: 

      Tape the screwdriver tip before use.

  30. REMOVE ENGINE WATER PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 18

  31. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Remove the 15 bolts and 2 nuts.
      GTY441623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
    2. Remove the timing chain cover sub-assembly by prying between the timing chain cover sub-assembly and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver.
      GTY452574Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly, cylinder block sub-assembly and timing chain cover sub-assembly.

      HINT: 

      Tape the screwdriver tip before use.

    3. Remove the gasket.
      GTY307825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE TIMING CHAIN COVER PLATE 
    1. Remove the 4 bolts, timing chain cover plate and timing chain cover plate gasket.
  33. REMOVE TIMING CHAIN CASE OIL SEAL 

    Refer to PROCEDURE - Step 3

  34. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Temporarily tighten the crankshaft pulley bolt.
    2. Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the center line of the block bore (Bank 1) (TDC/compression).
      GTY431915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Sensor Plate
      *b Center Line
      *c Timing Mark
    3. Check that the timing marks of the camshaft timing gear assembly and camshaft timing sprocket are aligned with the timing marks of the camshaft bearing caps as shown in the illustration.
      GTY436245Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark *b Viewpoint

      HINT: 

      For the intake camshaft:

      Be sure to check the mark (A) at the point where the marks (B), (C), and (D) are positioned in a line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

      GTY454373Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If not aligned, turn the crankshaft 1 revolution (360°) clockwise and align the timing marks as above.

  35. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Turn the stopper plate clockwise to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.
      GTY444669Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Plunger
      *b Stopper Plate
      *c Hexagon Wrench
    2. Turn the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
    3. Remove the 2 bolts and No. 1 chain tensioner assembly.
      GTY296347Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the chain tensioner slipper.
  37. REMOVE CHAIN SUB-ASSEMBLY 
    1. Turn the crankshaft 10° counterclockwise to loosen the chain sub-assembly of the crankshaft timing sprocket.
      GTY447091Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Sensor Plate
      *b Center Line
      *c Timing Mark
    2. Remove the crankshaft pulley bolt.
    3. Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft.
      GTY301808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) and set it as shown in the illustration.
      GTY456092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 1
      NOTE:

      Be sure to loosen the chain sub-assembly between the banks.

    5. Remove the chain sub-assembly.
  38. REMOVE IDLE SPROCKET ASSEMBLY 
    1. Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.
      GTY146516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE NO. 1 CHAIN VIBRATION DAMPER 
    1. Remove the 2 bolts and No. 1 chain vibration damper.
      GTY124072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE NO. 2 CHAIN VIBRATION DAMPER 
    1. Remove the 2 No. 2 chain vibration dampers.
  41. REMOVE CRANKSHAFT TIMING SPROCKET 
    1. Remove the crankshaft timing sprocket from the crankshaft.
      GTY191932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 pulley set keys from the crankshaft.
  42. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING SPROCKET AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1) 

    See step  46

  43. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY 

    See step  47

  44. REMOVE CAMSHAFT BEARING CAP (for Bank 1) 

    See step  48

  45. REMOVE CAMSHAFT 

    See step  49

  46. REMOVE NO. 2 CAMSHAFT 

    See step  50

  47. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH 

    See step  51

  48. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING SPROCKET AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2) 

    See step  52

  49. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY 

    See step  53

  50. REMOVE CAMSHAFT BEARING CAP (for Bank 2) 

    See step  54

  51. REMOVE NO. 3 CAMSHAFT 

    See step  55

  52. REMOVE NO. 4 CAMSHAFT 

    See step  56

  53. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH 

    See step  57

  54. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 

    See step  3

  55. REMOVE VALVE LASH ADJUSTER ASSEMBLY 

    See step  4

  56. REMOVE VALVE STEM CAP 
    1. Remove the valve stem caps from the valves.

      HINT: 

      Arrange the removed parts in the correct order.

  57. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH 

    See step  7

  58. REMOVE CYLINDER HEAD GASKET RH 

    See step  8

  59. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH 

    See step  9

  60. REMOVE CYLINDER HEAD GASKET LH 

    See step  10

  61. REMOVE WATER INLET PIPE 
    1. Slide the clip and disconnect the No. 1 water by-pass hose from the water inlet pipe.
    2. Remove the 2 bolts and water inlet pipe.
      GTY296346Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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