Engine Mechanical - 1MZ-FE: Removal & Installation Toyota Highlander I

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Removal

Refer to these figures throughout procedure. (Scheme 20)- (Scheme 25).

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-159178-S32699500612003111700000) . Raise and support vehicle. Remove front wheels. Remove engine under covers. Remove both front fender splash shields. Remove right front fender apron seal.
2. Drain cooling system and engine oil. Drain transaxle fluid. On AWD models, drain transfer case oil. Remove battery. Remove air conditioning compressor and power steering pump belts. Remove cruise control actuator and bracket.
3. Remove engine moving control rod. Remove right engine mounting bracket No. 2. Remove vacuum brake booster union-to-check valve hose. Remove V-bank cover. Remove air cleaner assembly with hose. Disconnect accelerator control cable assembly. Disconnect fuel pipe sub-assembly No. 1.
4. Remove radiator hose inlet and radiator hose outlet. Disconnect oil cooler inlet and outlet hoses. Disconnect heater inlet and outlet water hose. Remove glove box door assembly. Disconnect engine wire from ECU and junction block.
5. Disconnect floor shift transmission control cable assembly. Disconnect oil reservoir-to-pump hose No. 1. Disconnect steering gear outlet return tube. Remove front exhaust pipe assembly No. 2.
6. On AWD models, place reference marks on drive shaft flanges. Remove drive shaft with center bearing shaft assembly. Disconnect both front stabilizer link assembly. Remove both front axle hub nut.
7. Disconnect both speed sensors. Disconnect tie rod assemblies. Disconnect both front lower suspension arm sub-assemblies.
8. Remove starter assembly. Remove flex plate and torque converter clutch setting bolt.
9. Place reference marks on intermediate steering shaft sub-assembly. Disconnect intermediate steering shaft sub-assembly.
10. Remove generator assembly and generator bracket No. 2. Remove generator belt adjusting bar. Remove air conditioning compressor and magnetic clutch assembly and secure away for engine assembly removal. Remove engine assembly with transaxle.

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Installation

To install, reverse removal procedure. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS . When installing transaxle to engine, use threadlock sealant on ends of drive plate mounting bolts. When installing exhaust pipe, install NEW gaskets and mounting nuts. Refill fluids. Start engine and check for leaks. Road test vehicle.

1. Disconnect negative battery cable. Remove suspension upper brace. On AWD models, remove drive shaft. Remove right fender apron seal. Drain cooling system. Remove air cleaner cap assembly and air filter. Remove front exhaust pipe. Remove right engine mount stay.
2. Remove nuts, clips, and "V" bank cover. Remove air intake chamber assembly after disconnecting accelerator and throttle cables, TP sensor connector, IAC valve connector, and other wiring and hoses, as equipped.
3. Remove 6 injector connectors. Disconnect fuel inlet hose from fuel filter. Disconnect heater hose from intake manifold. Remove 9 bolts, 2 nuts and 2 plate washers. Remove intake manifold, delivery pipes and injectors assembly.
4. Disconnect wiring connectors and hoses from water outlet housing. Remove 2 bolts, 2 nuts and 2 plate washers and remove water outlet housing.
5. Remove generator drive belt. Remove power steering pump. Remove ignition coils. Remove spark plugs. Remove timing belt. Remove camshaft timing pulleys and No. 2 idler pulley.
6. Remove wiring clamps from rear timing belt cover. Remove 6 bolts and remove rear timing belt cover. Disconnect engine wiring and protectors from rear of engine, from both cylinder heads, and from water inlet. Disconnect engine wiring from right and left sides of engine.
7. Disconnect cylinder head rear plate from left cylinder head. Remove water inlet pipe from left cylinder head and water inlet. Discard "O" ring from inlet pipe.
8. Disconnect connectors from right exhaust manifold. Remove bolt, nut and manifold stay. Remove 6 nuts, right exhaust manifold. Discard gasket. Remove power steering pump bracket.
9. Disconnect connectors from left exhaust manifold. Remove bolt, nut and manifold stay. Remove 6 nuts, left exhaust manifold. Discard gasket. Remove camshaft position sensor.
10. Remove dipstick and guide. Remove and discard "O" ring from dipstick guide. Remove cylinder head covers and gaskets. Remove camshafts, if necessary. See «CAMSHAFTS»(ref-159178-S06751180662003111700000).
11. Using an 8-mm hexagon wrench, remove recessed cylinder head bolts. Loosen 8, 12-point cylinder head bolts in sequence using several steps. see scheme 36 Remove cylinder head.

Scheme 26

1. Install NEW cylinder head gaskets on cylinder block. Ensure identification mark is facing upward at lower corner of cylinder block. see scheme 14 Ensure all holes in cylinder head gaskets align with cylinder block. Install cylinder heads.
2. Apply engine oil on cylinder head bolt threads and cylinder head bolt-to-cylinder head contact surfaces. Install and tighten 12-point cylinder head bolts to specification in sequence using several passes. see scheme 36 See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000). Replace any bolt that cannot be tightened to specification. To reach final torque, put paint on front-facing part of bolt head, then tighten an additional 90 degrees as indicated.
3. Apply light coat of oil to threads of recessed head bolts. Install recessed cylinder head bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000). Install camshafts using proper procedure. See «CAMSHAFT»(ref-159178-S06751180662003111700000).
4. To install remaining components, reverse removal procedure. If camshaft or cylinder head components are serviced, adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(ref-159178-S22722080942003111700000) under ADJUSTMENTS. Install NEW gaskets on rear timing belt cover. (Scheme 27)
5. When installing intake manifold assembly, tighten bolts and nuts in sequence, using several passes to reach final specification. see scheme 37
6. Use NEW gaskets and "O" rings as removed. Ensure all bolts and nuts are tightened to specifications. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000). Adjust fluid levels and control cables.

Scheme 27

Remove camshaft. See CAMSHAFT . Note location of adjusting shims and valve lifters for reassembly reference. Remove adjusting shims and valve lifters from cylinder head.

To install, reverse removal procedure. Ensure components are installed in original location. If camshaft, adjusting shim or valve lifter are replaced, check valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS.

1. Remove cylinder head(s). See «CYLINDER HEAD»(ref-159178-S28934627302003111700000). Camshafts can be removed prior to cylinder head being removed from vehicle, if necessary, after removal of cylinder head covers. CAUTION: Since thrust clearance of camshaft is small, camshaft must be kept level during removal and handling. If not, thrust end of camshaft may crack cylinder head and/or break camshaft. Follow removal procedures carefully to avoid this damage.
2. When removing intake camshaft, align timing marks (2 dots) on camshaft gears by rotating camshaft using hex area of camshaft. (Scheme 28) Secure exhaust camshaft sub-gear to camshaft main gear with a 6 x 1.0 x 18 mm service bolt (this step will ensure torsional spring force of sub-gear is eliminated). (Scheme 29)
3. Uniformly loosen and remove 10 bearing cap bolts, in several passes, following sequence given. (Scheme 30) Remove 5 bearing caps and remove intake camshaft. DO NOT remove camshaft timing gear (VVT-i) unless replacement of VVT-i or camshaft is necessary. Repeat this procedure to remove exhaust camshaft, following proper bolt loosening sequence.
4. If disassembling exhaust camshaft, mount hexagonal area of camshaft in soft-jaw vise. Using holding tool on sub-gear, turn sub-gear counterclockwise and remove service bolt "A". (Scheme 31) Remove snap ring, wave washer, sub-gear and gear spring.

Scheme 28

Scheme 29

Scheme 30

Scheme 31

1. When assembling exhaust camshaft, install gear spring, sub-gear, wave washer and snap ring. Using spanner wrench, rotate sub-gear counterclockwise until holes in main gear and sub-gear are aligned. Ensure pins on the gears align with ends of gear spring. Install service bolt "A". (Scheme 29)
2. Apply grease to thrust surfaces and journals of camshafts. Install exhaust camshaft in cylinder head. Rotate exhaust camshaft so timing marks on cylinder head are positioned at 90 degree angle to cylinder head. (Scheme 32)
3. Apply grease to seal lip on NEW oil seal. Install oil seal on exhaust camshaft. Apply sealant on No. 1 exhaust camshaft bearing cap at bearing cap-to-cylinder head surface.
4. Install exhaust camshaft bearing caps in numerical order. Ensure arrow on top of camshaft bearing cap is pointing toward timing belt end of engine. see scheme 21
5. Coat camshaft bearing cap bolt-to-camshaft bearing cap surface and bolt threads with engine oil. Install and tighten exhaust camshaft bearing cap bolts to specification in sequence using several steps. see scheme 35 See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000).
6. Install intake camshaft in cylinder head. Rotate intake camshaft so timing mark on intake camshaft is aligned with timing mark on exhaust camshaft. (Scheme 28)
7. Install intake camshaft bearing caps in numerical order. Ensure arrow on top of camshaft bearing cap is pointing toward timing belt end of engine. see scheme 21
8. Coat camshaft bearing cap bolt-to-camshaft bearing cap surface and bolt threads with engine oil. Install and tighten intake camshaft bearing cap bolts to specification in sequence using several steps. see scheme 35 See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000). CAUTION: Ensure service bolt "A" is removed from sub-gear on exhaust camshafts.
9. Remove service bolt "A" from exhaust camshaft. Check and adjust valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(ref-159178-S22722080942003111700000) under ADJUSTMENTS.
10. Apply sealant to grooves of semi-circular plugs and install in cylinder head (if removed). (Scheme 26) Before installing valve cover and gasket, apply sealant at front and rear areas of cylinder head. see scheme 6
11. Using NEW gasket, install valve cover. Install and tighten valve cover bolts to specification in several steps. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000). To install remaining components, reverse removal procedure. Tighten all fasteners to specification. Fill cooling system and adjust control cables.

Scheme 32

Remove transaxle and drive plate. Using a knife, cut off oil seal lip. Pry oil seal from crankshaft rear oil seal housing. Use care not to damage sealing surfaces.

1. Ensure all sealing surfaces are clean. Apply grease to seal lip of oil seal. Install oil seal in crankshaft rear oil seal housing until oil seal is even with housing surface.
2. Apply Loctite to drive plate bolts. Install and tighten bolts to specification in a crisscross pattern. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000) . To install remaining components, reverse removal procedure.

1. Disconnect negative battery cable. Drain cooling system. Remove timing belt, camshaft sprockets and No. 2 idler pulley. See «TIMING BELT REPLACEMENT - 3.0L V6»(ref-155600) article in ENGINE.
2. Remove inner timing belt cover. Remove bolts/nuts, water pump and gasket.

To install, reverse removal procedure. Use NEW gaskets. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Ensure proper procedure is followed when installing timing belt. Fill cooling system.

1. Disconnect negative battery cable. Raise and support vehicle. Drain engine oil. Remove front exhaust pipe that fits between exhaust manifolds and catalytic converter.
2. Remove dipstick. Remove lower oil pan bolts and nuts. Install a cutter blade between upper and lower oil pans. Carefully tap seal cutter around lower oil pan to cut and loosen seal. DO NOT damage sealing surfaces. Remove lower oil pan.
3. Remove oil strainer and gasket. Remove exhaust pipe support stay and drive plate cover. Remove upper oil pan-to-transaxle bolts. Remove upper oil pan. Remove baffle plate, if necessary.

1. Ensure all pan and block sealing surfaces are clean. Apply a.16-.20 in. (4.0-5.0 mm) diameter bead of sealant on upper oil pan. (Scheme 33) Install upper oil pan. Install bolts and nuts and tighten, uniformly and in several passes, to specifications. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000).
2. Install drive plate cover and exhaust pipe support stay. Tighten bolts to specifications. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000).
3. Using NEW gasket, install pick-up tube. Install and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000).
4. Apply a.16-.20 in. (4.0-5.0 mm) diameter bead of sealant on lower oil pan. (Scheme 33) Install lower oil pan. Install bolts and nuts and tighten, uniformly and in several passes, to specification. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000).

Scheme 33

Removal & Disassembly

1. Remove right front wheel and fender apron seal. Drain oil. Remove front exhaust pipe and pipe bracket from upper oil pan.
2. Remove accessory drive belts and power steering pump bracket. Remove A/C compressor from engine mounting and position aside.
3. Remove timing belt. Remove camshaft timing sprockets and crankshaft timing sprocket. See «TIMING BELT REPLACEMENT - 3.0L V6»(ref-155600) article in ENGINE.
4. Remove inner timing belt cover from front of cylinder heads. Remove A/C compressor bracket.
5. Remove lower oil pan and strainer. Remove upper oil pan. See «OIL PAN»(ref-159178-S35370004672003111700000) under REMOVAL & INSTALLATION.
6. Remove baffle plate from upper oil pan. Remove crankshaft position sensor. Remove 9 bolts and remove oil pump, using a screwdriver to pry between oil pump and main bearing cap. Remove and discard "O" ring.
7. Remove relief valve plug, gasket, spring and relief valve from side of oil pump housing. Remove 9 screws and remove pump body cover, and drive and driven rotors.

Reassembly & Installation

1. To reassemble, reverse disassembly procedure. Ensure both rotors are installed in oil pump body with identification mark (triangle mark) facing oil pump body cover. Install oil pump body cover.
2. Using NEW gasket, install and tighten relief valve plug to specification. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000) . Using seal installer tool, install crankshaft front seal (if removed) until seal surface is even with oil pump body. Coat seal lip with grease.
3. To install, apply sealant on mating surface of oil pump. DO NOT apply excess sealant or allow sealant into bolt holes.
4. Install NEW "O" ring on cylinder block. Install oil pump. Ensure splined teeth on drive rotor of oil pump engage with splines on crankshaft. Install and tighten bolts, in several passes, to specification. See «TORQUE SPECIFICATIONS»(ref-159178-S17585881052003111700000) .
5. Install crankshaft position sensor, upper oil pan with baffle plate, oil strainer, and lower oil pan. See «OIL PAN»(ref-159178-S35370004672003111700000) under REMOVAL & INSTALLATION. Install remaining components in reverse of removal procedure. Start engine and check pump for leaks.

Scheme 34