2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL; 2016 MY Sienna [12/2015

Last Modified: 04-05-2023	6.11:8.1.0	Doc ID: RM100000000VIDL
Model Year Start: 2016	Model: Sienna	Prod Date Range: [12/2015 - 08/2016]
Title: 2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL; 2016 MY Sienna [12/2015 - 08/2016]

REMOVAL

PROCEDURE

1. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

3. DISCHARGE FUEL SYSTEM PRESSURE

(See page )

4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See page ).

5. REMOVE INSTRUMENT PANEL FINISH PANEL END LH

6. REMOVE FRONT WHEEL

7. REMOVE NO. 1 ENGINE UNDER COVER

8. REMOVE NO. 2 ENGINE UNDER COVER (for AWD)

9. REMOVE FRONT FENDER APRON SEAL LH

(a) Remove the bolt, 2 clips and front fender apron seal LH.

10. REMOVE FRONT FENDER APRON SEAL RH

(a) Remove the 2 bolts, clip and front fender apron seal RH.

11. DRAIN ENGINE OIL

12. DRAIN ENGINE COOLANT

13. DRAIN AUTOMATIC TRANSAXLE FLUID (for 2WD)

14. DRAIN AUTOMATIC TRANSAXLE FLUID (for AWD)

15. DRAIN TRANSFER OIL (for AWD)

16. REMOVE FRONT WIPER ARM HEAD CAP

17. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH

18. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH

19. REMOVE FRONT FENDER TO COWL SIDE SEAL LH

20. REMOVE FRONT FENDER TO COWL SIDE SEAL RH

21. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

22. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

23. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

24. REMOVE V-BANK COVER SUB-ASSEMBLY

(a) Hold the front of the V-bank cover sub-assembly and raise it to disengage the 2 retainers on the front of the V-bank cover sub-assembly. Continue to raise the V-bank cover sub-assembly to disengage the 2 retainers on the rear of the V-bank cover sub-assembly and remove the V-bank cover sub-assembly.

NOTICE:

Attempting to disengage both front and rear retainers at the same time may cause the V-bank cover sub-assembly to break.

25. REMOVE AIR CLEANER INLET COVER ASSEMBLY SEAL

(a) Disconnect the 3 vacuum hose clamps from the air cleaner inlet cover assembly seal.

(b) Remove the 2 bolts and air cleaner inlet cover assembly seal.

26. REMOVE BATTERY

(a) Disconnect the positive (+) cable from the positive (+) battery terminal.

(b) Loosen the nut, and remove the bolt from the battery clamp.

27. REMOVE AIR CLEANER AND HOSE

28. DISCONNECT ENGINE WIRE

(a) Remove the relay block cover.

(b) Remove the 2 bolts and separate the 2 ground wires.

(d) Remove the nut.

(e) Using a screwdriver, unlock the claw and separate the engine wire from the engine room relay block.

(f) Pull up the lever to disconnect the ECM connector.

29. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Remove the nut from the control shaft lever.

(b) Using a screwdriver, disengage the 4 claws and disconnect the control cable with clip from the control cable bracket.

30. DISCONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Disconnect the No. 1 fuel vapor feed hose.

31. DISCONNECT NO. 1 RADIATOR HOSE

(a) Disconnect the No. 1 radiator hose.

(b) Separate the No. 1 radiator hose from the radiator pipe clamp.

32. DISCONNECT NO. 2 RADIATOR HOSE

(a) Disconnect the No. 2 radiator hose.

33. DISCONNECT INLET HEATER WATER HOSE

(a) Disconnect the inlet heater water hose.

34. DISCONNECT OUTLET HEATER WATER HOSE

(a) Disconnect the outlet heater water hose.

35. DISCONNECT FUEL MAIN TUBE

(a) Remove the No. 1 fuel pipe clamp.

(b) Disconnect the connector from the pipe by hand. When the connector and the pipe are stuck, push in and pull on the connector to release it. Pull the connector out of the pipe carefully.

Text in Illustration

	Pinch
	Pull

NOTICE:

Check for any dirt and foreign matter contamination in the pipe and around the connector. Clean if necessary. Foreign matter may damage the O-rings or cause leaks in the seal between the pipe and connector.
Do not use any tools to separate the pipe and connector.
Do not forcefully bend or twist the nylon tube.
Check for any dirt and foreign matter on the pipe seal surface. Clean if necessary.
Put the pipe and connector ends in plastic bags to prevent damage and dirt contamination.
If the pipe and connector are stuck together, pinch the tube between your fingers and turn it carefully to free it. Then disconnect the hose.

36. DISCONNECT UNION TO CHECK VALVE HOSE

(a) Disconnect the union to check valve hose.

37. DISCONNECT NO. 1 TRANSMISSION OIL COOLER HOSE ASSEMBLY

(a) Disconnect the No. 1 transmission oil cooler hose from the radiator.

38. DISCONNECT OUTLET OIL COOLER HOSE

(a) Disconnect the outlet oil cooler hose from the radiator.

39. REMOVE NO. 2 ENGINE MOUNTING STAY RH

(a) Remove the 2 bolts and separate the No. 2 ground wire from the cylinder head cover sub-assembly.

(b) Remove the bolt, 2 nuts and No. 2 engine mounting stay RH from the front No. 1 engine mounting bracket LH.

40. REMOVE ENGINE MOVING CONTROL ROD BRACKET

(a) Remove the 3 bolts and engine moving control rod bracket together engine moving control rod from the front No. 1 engine mounting bracket LH and vehicle.

41. REMOVE ENGINE MOVING CONTROL ROD

HINT:

Perform this procedure only when replacement of the engine moving control rod is necessary.

(a) Remove the bolt and engine moving control rod from the engine moving control rod bracket.

42. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY

43. DISCONNECT SUCTION HOSE SUB-ASSEMBLY

44. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

(See page )

45. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for 2WD)

46. REMOVE FRONT EXHAUST PIPE ASSEMBLY (for AWD)

47. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET

(a) Remove the 2 nuts and No. 1 exhaust pipe support bracket from the oil pan sub-assembly.

48. SECURE STEERING WHEEL

49. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY

50. REMOVE FRONT AXLE SHAFT NUT LH

51. REMOVE FRONT AXLE SHAFT NUT RH

HINT:

Perform the same procedure as for the LH side.

52. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH

53. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

54. SEPARATE FRONT SPEED SENSOR LH

55. SEPARATE FRONT SPEED SENSOR RH

HINT:

Perform the same procedure as for the LH side.

56. SEPARATE TIE ROD ASSEMBLY LH

57. SEPARATE TIE ROD ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

58. SEPARATE FRONT LOWER SUSPENSION ARM LH

59. SEPARATE FRONT LOWER SUSPENSION ARM RH

HINT:

Perform the same procedure as for the LH side.

60. SEPARATE FRONT DRIVE SHAFT ASSEMBLY

61. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

62. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)

63. REMOVE FLYWHEEL HOUSING UNDER COVER

(a) Remove the 2 bolts and flywheel housing under cover.

64. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

(a) Using SST, hold the crankshaft pulley.

SST: 09213-70011

09213-70020

SST: 09330-00021

(b) Remove the 6 drive plate and torque converter clutch setting bolts.

65. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine lifter.

NOTICE:

Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
Securely support the engine assembly to prevent it from turning upside down until it is secured to an engine stand.
Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.

(b) Remove the 2 clamps and separate the front fender liner LH and RH from the frame side rail plates LH and RH.

Text in Illustration

Nut

(d) Remove the 6 bolts, 2 nuts and front suspension member rear braces LH and RH.

(e) Operate the engine lifter, then remove the engine assembly from the vehicle.

NOTICE:

Make sure that the engine is clear of all wiring and hoses.
While lowering the engine from the vehicle, do not allow it to contact the vehicle.

(f) Install the 2 engine hangers with the 4 bolts.

Text in Illustration

*1	No. 1 Engine Hanger
*2	No. 2 Engine Hanger
*a	for Bank 1
*b	for Bank 2

Torque:

33 N·m {337 kgf·cm, 24 ft·lbf}

Part No.

Item	Part No.
No. 1 engine hanger	12281-31120
No. 2 engine hanger	12282-31100
Bolt	91671-10825

(g) Attach the sling device to the engine hangers and chain block.

66. REMOVE FAN AND GENERATOR V BELT

67. REMOVE GENERATOR ASSEMBLY

68. REMOVE COOLER COMPRESSOR ASSEMBLY

69. REMOVE STARTER ASSEMBLY

70. REMOVE FLEXIBLE HOSE BRACKET SUB-ASSEMBLY

(a) Separate the breather plug hose and sensor wire from the flexible hose bracket sub-assembly.

(b) Remove the bolt and flexible hose bracket sub-assembly.

71. REMOVE ENGINE WIRE

(a) Remove the engine wire from the engine with transaxle.

72. REMOVE NO. 1 FRONT STABILIZER BRACKET LH (for AWD)

73. REMOVE NO. 1 FRONT STABILIZER BRACKET RH (for AWD)

HINT:

Perform the same procedure as for the LH side.

74. REMOVE FRONT STABILIZER BAR (for AWD)

75. REMOVE STEERING GEAR ASSEMBLY (for AWD)

76. SEPARATE FRONT ENGINE MOUNTING INSULATOR

(a) Disconnect the wire clamp and connector.

(b) Remove the bolt and separate the front engine mounting insulator.

77. SEPARATE ENGINE MOUNTING INSULATOR LH

(a) Remove the nut and separate the engine mounting insulator LH.

78. SEPARATE ENGINE MOUNTING INSULATOR RH

(a) Remove the nut and separate the engine mounting insulator RH.

79. SEPARATE REAR ENGINE MOUNTING INSULATOR ASSEMBLY (for AWD)

(a) Remove the 2 bolts and separate the rear engine mounting insulator assembly.

NOTICE:

Do not remove the rear engine mounting insulator assembly through bolts. Doing so makes it difficult to install the rear engine mounting insulator assembly.