Last Modified: 04-05-2023 6.11:8.1.0 Doc ID: RM100000000VID0
Model Year Start: 2016 Model: Sienna Prod Date Range: [12/2015 - 08/2016]
Title: 2GR-FE ENGINE MECHANICAL: ENGINE UNIT: DISASSEMBLY; 2016 MY Sienna [12/2015 - 08/2016]

DISASSEMBLY

PROCEDURE

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY

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

2. REMOVE SPARK PLUG

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE (ENGINE CONTROL): IGNITION COIL AND SPARK PLUG: REMOVAL+

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 VVT SENSOR

(See page 2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE (ENGINE CONTROL): CAMSHAFT POSITION SENSOR: REMOVAL )

6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

(See page 2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE (ENGINE CONTROL): CAMSHAFT OIL CONTROL VALVE: REMOVAL )

7. REMOVE CRANKSHAFT POSITION SENSOR

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE (ENGINE CONTROL): CRANKSHAFT POSITION SENSOR: REMOVAL+

8. REMOVE NO. 1 OIL PIPE

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

Text in Illustration

*1

Oil Pipe Union

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

9. REMOVE OIL PIPE

(a) Remove the bolt.

Text in Illustration

*1

Oil Pipe Union

*2

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

Text in Illustration

*a

for Bank 1

*b

for Bank 2

(a) Remove the 2 cylinder block water drain cock sub-assemblies from the cylinder block.

(b) Remove the 2 cylinder block water drain cock plugs from the 2 water drain cock sub-assemblies.

11. REMOVE OIL FILTER ELEMENT

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE LUBRICATION: OIL AND OIL FILTER: REPLACEMENT+

12. REMOVE CRANKSHAFT PULLEY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: FRONT CRANKSHAFT OIL SEAL: REMOVAL+

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.

Text in Illustration

*1

Clip

*2

Clamp

*3

Bolt

(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 the No. 1 oil cooler bracket.

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

Text in Illustration

*1

Nut

*2

Bolt

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

15. REMOVE ENGINE OIL DIPSTICK GUIDE (w/ Oil Cooler)

(a) Remove the engine oil dipstick guide.

(b) Remove the O-ring.

16. REMOVE ENGINE OIL DIPSTICK GUIDE (w/o Oil Cooler)

(a) Remove the bolt and engine oil dipstick guide.

(b) Remove the O-ring.

17. REMOVE NO. 1 FRONT ENGINE MOUNTING BRACKET LH

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

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

18. REMOVE WATER INLET HOUSING

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

(b) Remove the gasket.

(c) Remove the 2 stud bolts.

(d) Separate the No. 1 water by-pass hose from the water inlet housing.

(e) Remove the drain cock plug.

Text in Illustration

*1

Nut

*2

Bolt

(f) Remove the drain cock assembly.

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

(h) Remove the 2 O-rings.

19. REMOVE WATER OUTLET

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

Text in Illustration

*1

Nut

*2

Bolt

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

20. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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

(b) Remove the 3 gaskets.

21. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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

Text in Illustration

*1

Baffle Plate

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 LH.

(b) Remove the 3 gaskets.

22. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.

Text in Illustration

*1

Nut

(b) Insert the blade of the 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 an E6 "TORX" socket wrench, remove the 2 stud bolts.

23. REMOVE OIL STRAINER SUB-ASSEMBLY

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

Text in Illustration

*1

Bolt

*2

Nut

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

24. REMOVE OIL PAN SUB-ASSEMBLY

(a) Remove the 16 bolts and 2 nuts.

Text in Illustration

*1

Nut

*a

w/o Oil Cooler

*b

w/ Oil Cooler

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.

Text in Illustration

*1

Protective Tape

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 an E8 "TORX" socket wrench, remove the 4 stud bolts.

25. REMOVE NO. 1 OIL PAN BAFFLE PLATE

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

26. REMOVE ENGINE REAR OIL SEAL RETAINER

(a) Remove the 6 bolts.

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

Text in Illustration

*1

Protective Tape

Pry

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

27. REMOVE ENGINE REAR OIL SEAL

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

Text in Illustration

*1

Protective Tape

*2

Wooden Block

HINT:

Tape the screwdriver tip before use.

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

NOTICE:

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

HINT:

Tape the screwdriver tip before use.

28. REMOVE WATER PUMP ASSEMBLY

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

29. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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

Text in Illustration

*1

Nut

(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.

Text in Illustration

*1

Protective Tape

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.

30. REMOVE TIMING CHAIN CASE OIL SEAL

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

Text in Illustration

*1

Protective Tape

*2

Wooden Block

HINT:

Tape the screwdriver tip before use.

31. SET NO. 1 CYLINDER TO TDC/COMPRESSION

(a) Temporarily tighten the pulley set bolt.

(b) Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).

Text in Illustration

*1

Sensor Plate

*a

Center Line

*b

Timing Mark

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

Text in Illustration

*a

Timing Mark

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

32. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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

Text in Illustration

*1

Plunger

*2

Stopper Plate

*3

Pin

(b) Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm diameter (0.0500 in.) into the stopper plate hole.

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

33. REMOVE CHAIN TENSIONER SLIPPER

(a) Remove the chain tensioner slipper.

34. REMOVE CHAIN SUB-ASSEMBLY

(a) Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket.

Text in Illustration

*1

Sensor Plate

*a

Center Line

*b

Timing Mark

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

Text in Illustration

*a

for Bank 1

(e) Remove the chain sub-assembly.

35. REMOVE IDLE SPROCKET ASSEMBLY

(a) Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.

36. REMOVE NO. 1 CHAIN VIBRATION DAMPER

(a) Remove the 2 bolts and No. 1 chain vibration damper.

37. REMOVE NO. 2 CHAIN VIBRATION DAMPER

(a) Remove the 2 No. 2 chain vibration dampers.

38. REMOVE CRANKSHAFT TIMING SPROCKET

(a) Remove the crankshaft timing sprocket from the crankshaft.

(b) Remove the 2 keys from the crankshaft.

39. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL+

40. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL+

41. REMOVE CAMSHAFT BEARING CAP (for Bank 1)

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL+

42. REMOVE CAMSHAFT

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL+

43. REMOVE NO. 2 CAMSHAFT

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL+

44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL+

45. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL+

46. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL+

47. REMOVE CAMSHAFT BEARING CAP (for Bank 2)

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL+

48. REMOVE NO. 3 CAMSHAFT

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL+

49. REMOVE NO. 4 CAMSHAFT

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL+

50. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CAMSHAFT: REMOVAL+

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

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: REMOVAL+

52. REMOVE VALVE LASH ADJUSTER ASSEMBLY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: REMOVAL+

53. REMOVE VALVE STEM CAP

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: REMOVAL+

54. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: REMOVAL+

55. REMOVE CYLINDER HEAD GASKET RH

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: REMOVAL+

56. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: REMOVAL+

57. REMOVE CYLINDER HEAD GASKET LH

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: CYLINDER HEAD GASKET: REMOVAL+

58. REMOVE WATER INLET PIPE

(a) Remove 2 clamps and separate the No. 1 water by-pass hose.

(b) Remove the 2 bolts and water inlet pipe.

Text in Illustration

*a

w/o Oil Cooler

*b

w/ Oil Cooler