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Home >> Toyota >> 2016 >> Highlander LE Plus, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2GR-FE) (Service Information) (Except Hybrid) (2 Of 2) >> Engine Unit >> Disassembly [12/2013 - 11/2016] >> Procedure

Disassembly [12/2013 - 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 VENTILATION VALVE SUB-ASSEMBLY 
    1. Remove the ventilation valve sub-assembly.
      GTY439178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 2

  6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 3

  7. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 4

  8. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 5

  9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 3

  10. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 4

  11. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 5

  12. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 6

  13. REMOVE CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 2

  14. 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.
  15. 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.
  16. 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
  17. 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.
  18. REMOVE OIL FILTER CAP ASSEMBLY 

    Refer to PROCEDURE - Step 2

  19. REMOVE CRANKSHAFT PULLEY 

    Refer to PROCEDURE - Step 2

  20. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler) 

    Refer to PROCEDURE - Step 4

  21. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) 
    1. Remove the 3 bolts, 3 nuts, and oil cooler pipe with No. 1 oil cooler bracket and gasket.
      GTY438447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.
      GTY433118Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
      *b Bolt
    3. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
    4. Using an E7 "TORX" socket wrench, remove the stud bolt.
  22. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. w/o Oil Cooler:
      1. Remove the bolt and engine oil level dipstick guide.
        GTY446805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. w/ Oil Cooler:
      1. Remove the engine oil level dipstick guide.
        GTY299596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the O-ring.
      GTY452297Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH 
    1. Remove the 6 bolts and No. 1 front engine mounting bracket LH.
      GTY432537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
  24. REMOVE WATER OUTLET 
    1. Remove the 2 bolts, 4 nuts and water outlet.
      GTY441951Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
      *b Bolt
    2. Remove the 2 gaskets and O-ring.
      GTY295919Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.
      GTY431004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Seal Washer
    2. Remove the 3 gaskets.
      GTY439216Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. 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.
      GTY448386Courtesy 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.
      GTY439262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE WATER INLET HOUSING 
    1. Remove the 2 nuts, water inlet and thermostat.
      GTY439183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gasket.
    3. Remove the 2 stud bolts.
    4. Disconnect the No. 1 water by-pass hose from the water inlet housing.
    5. Remove the drain cock plug.
      GTY429357Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
      *b Bolt
    6. Remove the drain cock assembly.
    7. Remove the 2 bolts, nut, and water inlet housing.
    8. Remove the 2 O-rings.
      GTY146501Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY 
    1. Remove the 16 bolts and 2 nuts.
      GTY455537Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 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.
  29. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.
      GTY438475Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
      *b Nut
    2. Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the oil pan sub-assembly.
  30. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the oil pan sub-assembly.

      Refer to PROCEDURE - Step 30

    2. w/o Oil Cooler:
      1. Using an E8 "TORX" socket wrench, remove the 2 stud bolts.
        GTY549768Courtesy 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 20 mm (0.787 in.) *d 13 mm (0.512 in.)
        *e 35 mm (1.38 in.) - -
    3. w/ Oil Cooler:
      1. Using an E8 "TORX" socket wrench, remove the 4 stud bolts.
        GTY543353Courtesy 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 *d 20 mm (0.787 in.)
        *e 13 mm (0.512 in.) *f 35 mm (1.38 in.)
  31. 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
  32. 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.

  33. 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.

  34. REMOVE ENGINE WATER PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 17

  35. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY 
    1. Remove the 15 bolts and 2 nuts shown in the illustration.
      GTY439853Courtesy 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.
      GTY451161Courtesy 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 4 bolts, timing chain cover plate and timing chain cover plate gasket.
    4. Remove the gasket.
      GTY307825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE TIMING CHAIN CASE OIL SEAL 

    Refer to PROCEDURE - Step 3

  37. 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 exhaust gear assembly are aligned with the timing marks of the camshaft bearing caps as shown in the illustration.
      GTY456109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark

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

  38. 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.
      GTY454915Courtesy 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.
      GTY450128Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the chain tensioner slipper.
  40. 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.
      GTY425021Courtesy 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.
  41. 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
  42. REMOVE NO. 1 CHAIN VIBRATION DAMPER 
    1. Remove the 2 bolts and No. 1 chain vibration damper.
      GTY124072Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE NO. 2 CHAIN VIBRATION DAMPER 
    1. Remove the 2 No. 2 chain vibration dampers.
  44. 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.
  45. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1) 

    Refer to PROCEDURE - Step 38

  46. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 39

  47. REMOVE CAMSHAFT BEARING CAP (for Bank 1) 

    Refer to PROCEDURE - Step 40

  48. REMOVE CAMSHAFT 

    Refer to PROCEDURE - Step 41

  49. REMOVE NO. 2 CAMSHAFT 

    Refer to PROCEDURE - Step 42

  50. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 43

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

    Refer to PROCEDURE - Step 44

  52. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 45

  53. REMOVE CAMSHAFT BEARING CAP (for Bank 2) 

    Refer to PROCEDURE - Step 46

  54. REMOVE NO. 3 CAMSHAFT 

    Refer to PROCEDURE - Step 47

  55. REMOVE NO. 4 CAMSHAFT 

    Refer to PROCEDURE - Step 48

  56. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 49

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

    Refer to PROCEDURE - Step 2

  58. REMOVE VALVE LASH ADJUSTER ASSEMBLY 

    Refer to PROCEDURE - Step 3

  59. REMOVE VALVE STEM CAP 

    Refer to PROCEDURE - Step 4

  60. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH 

    Refer to PROCEDURE - Step 6

  61. REMOVE CYLINDER HEAD GASKET RH 

    Refer to PROCEDURE - Step 7

  62. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  63. REMOVE CYLINDER HEAD GASKET LH 

    Refer to PROCEDURE - Step 9

  64. 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.
      GTY430430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A w/o Oil Cooler
      *B w/ Oil Cooler
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