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Home >> Toyota Truck >> 2011 >> Highlander 2WD V6-3.5L (2GR-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Overhaul >> Disassembly >> Part 1

Part 1





2GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

(a) Remove the oil filler cap sub-assembly and oil filler gasket.

2. REMOVE SPARK PLUG

(a) Remove the 6 spark plugs.





3. REMOVE OIL PAN DRAIN PLUG

(a) Remove the oil pan drain plug and oil pan drain plug gasket.





4. REMOVE VENTILATION VALVE SUB-ASSEMBLY

(a) Remove the ventilation valve sub-assembly.





5. REMOVE CAMSHAFT POSITION SENSOR

(a) Remove the 4 bolts and 4 camshaft position sensors.





6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(a) Remove the 4 bolts and 4 camshaft timing oil control valves.





7. REMOVE CRANKSHAFT POSITION SENSOR

(a) Remove the bolt and crankshaft position sensor.





8. REMOVE NO. 1 OIL PIPE

(a) Remove the 2 oil pipe unions, gaskets and No. 1 oil pipe.





(b) Remove the oil control valve filter LH and gaskets.

9. REMOVE OIL PIPE

(a) Remove the bolt.





(b) Remove the 2 oil pipe unions and oil pipe.

(c) Remove the oil control valve filter RH and gaskets.

10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

(a) Remove the cylinder block water drain cock sub-assemblies from the cylinder block.





(b) Remove the cylinder block water drain cock plugs from the water drain cock sub-assemblies.

11. REMOVE OIL FILTER ELEMENT

(a) Remove the drain plug.





NOTICE:
Do not remove the O-ring from the oil filter cap.

(b) Connect the hose to the pipe.





(c) Insert the pipe with the hose into the oil filter cap.

(d) Make sure that the oil is completely drained and remove the pipe and O-ring.

(e) Using SST, remove the oil filter cap sub-assembly.





SST : 09228-06501

(f) Remove the oil filter element and O-ring from the oil filter cap sub-assembly.





NOTICE:
Do not use any tools when removing the O-ring to prevent the O-ring groove from being damaged.

12. REMOVE CRANKSHAFT PULLEY

(a) Using SST, loosen the crankshaft pulley bolt.





SST : 09213-70011

09213-70020

SST : 09330-00021

(b) Using SST, remove the crankshaft pulley bolt and crankshaft pulley.





SST : 09950-50013

09951-05010

09952-05010

09953-05020

09954-05021

13. REMOVE OIL COOLER ASSEMBLY (w/ OIL COOLER)

(a) Remove the bolt, 2 clamps, and 4 clips and disconnect the 2 water by-pass hoses.





(b) Remove the union bolt, oil cooler assembly, and O-ring.





14. REMOVE NO. 1 OIL COOLER BRACKET (w/ OIL COOLER)

(a) Remove the 3 bolts, 3 nuts, and oil cooler pipe with No. 1 oil cooler bracket.





(b) Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.





(c) Using a "TORX" socket wrench E8, remove the 2 stud bolts.

15. REMOVE NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Remove the bolt and No. 1 engine oil level dipstick guide.

(b) Remove the O-ring.





16. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH

(a) Remove the 6 bolts and No. 1 front engine mounting bracket LH.





(b) Using a "TORX" socket wrench E8, remove the 2 stud bolts.

17. REMOVE WATER INLET HOUSING

(a) Remove the 2 nuts, water inlet and thermostat.





(b) Remove the gasket.

(c) Remove the drain cock plug.

(d) Remove the drain cock assembly.

(e) Remove the 2 stud bolts.

(f) Separate the No. 1 water by-pass hose.

(g) Remove the 2 bolts, nut and water inlet housing.





(h) Remove the 2 O-rings.





18. REMOVE WATER OUTLET

(a) Remove the 2 bolts, 4 nuts and water outlet.





(b) Remove the 2 gaskets and O-ring.





19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

(a) Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.





(b) Remove the 3 gaskets.





20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

(a) Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.





NOTICE:
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.

(b) Remove the 3 gaskets.





21. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.





(b) Insert the blade of oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.





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

(c) Using a "TORX" socket wrench E6, remove the 2 stud bolts.

22. REMOVE OIL STRAINER SUB-ASSEMBLY

(a) Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.





(b) Using a "TORX" socket wrench E6, remove the 2 stud bolts.

23. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.





HINT
Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

(b) Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver.





NOTICE:
Be careful not to damage the contact surfaces of the cylinder block and oil pan.

HINT
Tape the screwdriver tip before use.

(c) Remove the 2 O-rings.





(d) Using a "TORX" socket wrench E8, remove the 2 stud bolts.

24. REMOVE NO. 1 OIL PAN BAFFLE PLATE

(a) Remove the 7 bolts and No. 1 oil pan baffle plate.





25. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 6 bolts.





(b) Using a screwdriver, pry out the engine rear oil seal retainer.





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

HINT
Tape the screwdriver tip before use.

26. REMOVE ENGINE REAR OIL SEAL

(a) Place the engine rear oil seal retainer on wooden blocks.





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

(b) Using a screwdriver and a hammer, tap out the oil seal.

HINT
Tape the screwdriver tip before use.

27. REMOVE WATER PUMP ASSEMBLY

(a) Remove the 16 bolts, water pump assembly and water pump gasket.





28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

(a) Remove the 15 bolts and 2 nuts as shown in the illustration.





(b) Remove the timing chain cover sub-assembly by prying between the timing chain cover and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver.





NOTICE:
Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

HINT
Tape the screwdriver tip before use.

(c) Remove the 4 bolts, chain cover plate and chain cover plate gasket.

(d) Remove the gasket.





29. REMOVE TIMING CHAIN CASE OIL SEAL

(a) Using a screwdriver, pry out the timing chain case oil seal.





HINT
Tape the screwdriver tip before use.

30. SET NO. 1 CYLINDER TO TDC / COMPRESSION

(a) Temporarily tighten the pulley set bolt.

(b) Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC / compression).





(c) Check that the timing marks of the camshaft timing gears are aligned with those of the bearing cap as shown in the illustration.





If not, turn the crankshaft 1 revolution (360°) and align the timing marks as shown in the illustration.

31. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.





(b) Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm diameter (0.05 in.) into the stopper plate's hole.

(c) Remove the 2 bolts and No. 1 chain tensioner assembly.





32. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the chain tensioner slipper.

33. REMOVE CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft counterclockwise 10° to loosen the chain sub-assembly.





(b) Remove the pulley set bolt.

(c) Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft.





(d) Turn the camshaft timing gear assembly on the bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.




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