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Home >> Toyota >> 2016 >> Highlander Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 9 (Engine Mechanical (1AR-FE) (Service Information) (Except Hybrid) (2 Of 2)) >> Engine Unit >> Disassembly [12/2013 - ] >> Procedure

Disassembly [12/2013 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE ENGINE COVER JOINT 
    1. Remove the 3 engine cover joints.
      GTY312223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE SPARK PLUG 

    Refer to PROCEDURE - Step 3

  3. REMOVE OIL FILLER CAP SUB-ASSEMBLY 
    1. Remove the oil filler cap sub-assembly from the cylinder head cover sub-assembly.
    2. Remove the gasket from the oil filler cap sub-assembly.
  4. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side) 

    Refer to PROCEDURE - Step 2

  5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side) 

    Refer to PROCEDURE - Step 3

  6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side) 

    Refer to PROCEDURE - Step 2

  7. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side) 

    Refer to PROCEDURE - Step 3

  8. REMOVE PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 

    Refer to PROCEDURE - Step 2

  9. REMOVE VENTILATION CASE SUB-ASSEMBLY 
    1. Remove the 8 bolts and 2 nuts.
      GTY451717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
      *b Nut
    2. Remove the ventilation case sub-assembly by prying between the ventilation case sub-assembly and cylinder block sub-assembly with a screwdriver.
      GTY188620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the contact surfaces of the cylinder block sub-assembly and ventilation case sub-assembly.

      HINT: 

      Tape the screwdriver tip before use.

  10. REMOVE SEPARATOR CASE 
    1. Remove the 2 bolts, separator case and gasket.
      GTY430039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE NO. 1 WATER BY-PASS PIPE 
    1. Remove the bolt, 2 nuts and No. 1 water by-pass pipe and gasket.
      GTY438195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
      *b Bolt
  12. REMOVE WATER INLET 

    Refer to PROCEDURE - Step 4

  13. REMOVE THERMOSTAT 

    Refer to PROCEDURE - Step 5

  14. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the bolt and V-ribbed belt tensioner assembly.
      GTY314503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE ENGINE WATER PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 4

  16. REMOVE WATER INLET HOUSING 
    1. Remove the 4 bolts, nut and water inlet housing and gasket.
      GTY440625Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Bolt
      *b Nut
  17. REMOVE CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 2

  18. REMOVE CRANKSHAFT PULLEY 
    1. Using SST, hold the crankshaft pulley and loosen the crankshaft pulley bolt. Further loosen the crankshaft pulley bolt until 2 or 3 threads are screwed into the crankshaft.
      GTY433902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
      • SST: 09213-54015 
      • SST: 09330-00021 

      HINT: 

      SST (crankshaft pulley holding tool) fixing bolt part No.: 91551-80650 (2 pcs)

    2. Using SST and the crankshaft pulley bolt, remove the crankshaft pulley and crankshaft pulley bolt.
      GTY455596Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Pulley Bolt
      *a Hold
      *b Turn
      • SST: 09950-50013 
        1. 09951-05010
        2. 09952-05010
        3. 09953-05020
        4. 09954-05011

      HINT: 

      Apply lubricant to the threads and end of SST.

  19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Remove the 16 bolts, 3 seal washers and cylinder head cover sub-assembly and cylinder head cover gasket.
      GTY428156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Seal Washer
    2. Remove the 3 camshaft bearing cap oil hole gaskets.
      GTY314686Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE SPARK PLUG TUBE GASKET 
    1. Using a screwdriver, pry out the 4 spark plug tube gaskets.
      GTY450481Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

      Be careful not to damage the cylinder head cover sub-assembly.

      HINT: 

      Tape the screwdriver tip before use.

  21. REMOVE ENGINE MOUNTING BRACKET RH 

    Refer to PROCEDURE - Step 6

  22. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 8

  23. REMOVE TIMING CHAIN COVER TIGHT PLUG 
    1. Using a 14 mm hexagon wrench, remove the timing chain cover tight plug and gasket.
      GTY312189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE TIMING CHAIN COVER PLATE 
    1. Remove the 4 bolts, timing chain cover plate and gasket.
      GTY312183Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE TIMING CHAIN COVER OIL SEAL 

    Refer to PROCEDURE - Step 9

  26. SET NO. 1 CYLINDER TO TDC/COMPRESSION 

    Refer to PROCEDURE - Step 12

  27. REMOVE TIMING CHAIN GUIDE 

    Refer to PROCEDURE - Step 13

  28. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 14

  29. REMOVE CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 15

  30. REMOVE CHAIN SUB-ASSEMBLY 
    1. Remove the chain sub-assembly.
  31. REMOVE NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 17

  32. REMOVE CRANKSHAFT TIMING SPROCKET 
    1. Remove the crankshaft timing sprocket from the crankshaft.
      GTY314227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 18

  34. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 19

  35. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 20

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

    Refer to PROCEDURE - Step 26

  37. REMOVE VALVE LASH ADJUSTER ASSEMBLY 

    Refer to PROCEDURE - Step 27

  38. REMOVE VALVE STEM CAP 

    Refer to PROCEDURE - Step 28

  39. REMOVE CAMSHAFT BEARING CAP 

    Refer to PROCEDURE - Step 21

  40. REMOVE CAMSHAFT 

    Refer to PROCEDURE - Step 24

  41. REMOVE OIL CONTROL VALVE FILTER 
    1. Remove the oil control valve filter from the No. 1 camshaft bearing cap.
      GTY384553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE NO. 1 CAMSHAFT BEARING 
    1. Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.
      GTY195088Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE NO. 2 CAMSHAFT BEARING 
    1. Remove the No. 2 camshaft bearing from the camshaft housing sub-assembly.
      GTY195089Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE CAMSHAFT HOUSING STUD BOLT 
    NOTE:

    If a camshaft housing stud bolt is deformed or its threads are damaged, replace it.

    1. Using an E8 "TORX" socket wrench, remove the stud bolt from the camshaft housing sub-assembly.
  45. REMOVE CAMSHAFT BEARING CAP SETTING RING PIN 
    NOTE:

    It is not necessary to remove the camshaft bearing cap setting ring pin unless it is being replaced.

    1. Remove the 10 camshaft bearing cap setting ring pins from the camshaft housing sub-assembly.
  46. REMOVE CAMSHAFT HOUSING STRAIGHT PIN 
    NOTE:

    It is not necessary to remove the camshaft housing straight pin unless it is being replaced.

    1. Remove the 2 straight pins from the camshaft housing sub-assembly.
  47. REMOVE CYLINDER HEAD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 29

  48. REMOVE CYLINDER HEAD GASKET 

    Refer to PROCEDURE - Step 30

  49. REMOVE CYLINDER BLOCK WATER JACKET SPACER 
    1. Remove the cylinder block water jacket spacer from the cylinder block sub-assembly.
      GTY312332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be sure to remove the cylinder block water jacket spacer. If it is not removed, it may fall and become damaged when the cylinder block sub-assembly is inverted.

  50. REMOVE OIL FILTER CAP ASSEMBLY 

    Refer to PROCEDURE - Step 2

  51. REMOVE OIL PAN DRAIN PLUG 
    1. Remove the oil pan drain plug and gasket from the oil pan sub-assembly.
  52. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Remove the 11 bolts and 2 nuts.
      GTY441057Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Nut
    2. Insert the blade of an oil pan seal cutter between the oil pan sub-assembly and stiffening crankcase assembly, cut through the applied sealer and remove the oil pan sub-assembly.
      GTY192227Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to damage the stiffening crankcase assembly contact surface of the oil pan sub-assembly.
      • Be careful not to damage the stiffening crankcase flange.
  53. REMOVE OIL STRAINER SUB-ASSEMBLY 
    1. Remove the 3 bolts, oil strainer sub-assembly and gasket.
      GTY184315Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE NO. 1 OIL PAN BAFFLE PLATE 
    1. Remove the 5 bolts and No. 1 oil pan baffle plate.
      GTY190555Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. INSPECT CRANKSHAFT BACKLASH 
    1. Using a dial indicator, measure the backlash of the crankshaft and balance shaft as shown in the illustration.
      GTY184440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Standard Backlash

      0.05 to 0.20 mm (0.00197 to 0.00787 in.)

      Maximum Backlash

      0.20 mm (0.00787 in.)

      If the backlash is more than the maximum, replace the engine balancer assembly.

  56. REMOVE ENGINE BALANCER ASSEMBLY 
    1. Remove the 7 bolts and engine balancer assembly.
      GTY195093Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not disassemble the engine balancer assembly.

  57. INSPECT NO. 1 BALANCE SHAFT THRUST CLEARANCE 

    See step  14

  58. INSPECT NO. 2 BALANCE SHAFT THRUST CLEARANCE 

    See step  15

  59. REMOVE STIFFENING CRANKCASE ASSEMBLY 
    1. Remove the 7 bolts.
      GTY195095Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver, remove the stiffening crankcase assembly by prying between the stiffening crankcase assembly and cylinder block sub-assembly at the places shown in the illustration.
      GTY452733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a LH Side
      *b RH Side
      NOTE:

      Be careful not to damage the contact surfaces of the cylinder block sub-assembly and stiffening crankcase assembly.

      HINT: 

      Tape the screwdriver tip before use.

  60. REMOVE STIFFENING CRANKCASE STUD BOLT 
    NOTE:

    If a stiffening crankcase stud bolt is deformed or its threads are damaged, replace it.

    1. Using an E5 and E8 "TORX" socket wrench, remove the 3 stud bolts from the stiffening crankcase assembly.
  61. REMOVE STIFFENING CRANKCASE RING PIN 
    NOTE:

    It is not necessary to remove the stiffening crankcase ring pin unless it is being replaced.

    1. Remove the 2 ring pins from the stiffening crankcase assembly.
  62. REMOVE REAR ENGINE OIL SEAL 
    1. Remove the rear engine oil seal from the cylinder block sub-assembly.
      GTY195097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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