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Home >> Toyota >> 2021 >> Highlander LE, 4WD >> Repair and Diagnosis >> Engine Mechanical >> Accessory Drive Belts >> Engine Mechanical System (2GR-FKS) - Service Information (1 Of 2) >> Camshaft >> Removal [12/2019 - 10/2022] >> Procedure

Removal [12/2019 - 10/2022]: Procedure

  1. INSTALL ENGINE ASSEMBLY TO ENGINE STAND 

    Refer to REMOVAL [12/2019 - 09/2020] , or refer to REMOVAL [09/2020 - 10/2022] 

  2. REMOVE ENGINE HANGERS 

    See step  70 [12/2019 - 09/2020], or see step  70 [09/2020 - 10/2022]

  3. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to REMOVAL [12/2019 - 10/2022]

  4. DISCONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 14

  5. DISCONNECT PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 15

  6. REMOVE NO. 2 SURGE TANK STAY 

    Refer to PROCEDURE - Step 16

  7. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 17

  8. REMOVE AIR SURGE TANK TO INTAKE MANIFOLD GASKET 

    Refer to PROCEDURE - Step 18

  9. REMOVE IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  10. REMOVE VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 11

  11. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 17

  12. REMOVE WIRE HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 20

  13. REMOVE WATER FILLER BRACKET 

    Refer to PROCEDURE - Step 21

  14. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 3

  15. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 5

  16. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 2

  17. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 7

  18. REMOVE VVT SENSOR (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 2

  19. REMOVE VVT SENSOR (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 3

  20. REMOVE VVT SENSOR (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 4

  21. REMOVE VVT SENSOR (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 5

  22. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 25

  23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 26

  24. REMOVE SPARK PLUG TUBE GASKET 

    Refer to PROCEDURE - Step 27

  25. REMOVE TIMING CHAIN COVER PLATE 

    Refer to PROCEDURE - Step 37

  26. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 
    1. Turn the crankshaft clockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the timing chain cover assembly.
      GTY685350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark (Cutout)
      *b "0" Timing Mark
    2. Check that the timing marks of the camshaft timing gear assemblies are aligned with the timing marks of the camshaft bearing caps as shown in the illustration.

      HINT: 

      If the marks are not aligned, turn the crankshaft again to align the marks.

      GTY658449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 2
      *B for Bank 1
      *a Timing Mark
      *b Paint Mark
    3. Place paint marks on the timing marks and sprockets of each camshaft timing gear assembly and on the links of the chain sub-assembly.

      HINT: 

      Be sure to place the paint marks on 2 links of the chain sub-assembly and on the sprockets of the camshaft timing gear assemblies at the locations of the timing marks of the camshaft timing gear assemblies.

  27. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Turn the crankshaft approximately 30° counterclockwise so that there is some slack in the chain sub-assembly.

      HINT: 

      This prevents the valves and pistons from interfering with each other.

      GTY634112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Align the hole in the lever of the No. 1 chain tensioner assembly with the hole in the tensioner body as shown in the illustration, and then insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole.
      GTY650461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lever Hole
      *b Tensioner Body
      *c Pin
      NOTE:

      Check that the pin is locked.

    3. Turn the crankshaft clockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the timing chain cover assembly.
      GTY685350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark (Cutout)
      *b "0" Timing Mark
    4. Remove the 2 bolts and No. 1 chain tensioner assembly from the cylinder head sub-assembly.
      NOTE:

      Do not drop the No. 1 chain tensioner assembly or bolts into the timing chain cover assembly.

      GTY639670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. DISCONNECT CHAIN SUB-ASSEMBLY (for Bank 1) 
    1. Turn the crankshaft clockwise until it is in the position shown in the illustration so that there is some slack in the chain sub-assembly between the banks.
      WARNING:

      As the camshafts may turn suddenly, do not touch the camshafts or camshaft timing gears.

      HINT: 

      When turning the crankshaft, engine oil may spray out of the oil holes.

      GTY667253Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain sub-assembly can be removed easily.

      HINT: 

      When turning the crankshaft, engine oil may spray out of the oil holes.

      GTY659707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 5 to 10°
    3. Remove the chain sub-assembly from the sprocket of the camshaft timing gear assembly and set it on the camshaft timing gear assembly.
      WARNING:

      As the camshaft may turn suddenly and pinch your fingers when the chain sub-assembly is removed, pinch the chain sub-assembly and lift it upward to remove it from the sprocket.

      GTY639713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. SEPARATE NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Remove the bolt to separate the No. 2 chain tensioner assembly from the camshaft housing sub-assembly.
      GTY639712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1) 
    1. Use a wrench to hold the hexagonal portion of the camshaft and remove the camshaft timing gear bolt from the camshaft timing gear assembly.
      GTY615988Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.
      • If the camshaft timing gear bolt has been struck or dropped, replace it.
  31. REMOVE CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1) 
    1. Use a wrench to hold the hexagonal portion of the No. 2 camshaft and remove the camshaft timing gear bolt from the camshaft timing exhaust gear assembly.
      NOTE:
      • Be careful not to damage the No. 2 camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.
      • If the camshaft timing gear bolt has been struck or dropped, replace it.
      GTY641390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
  32. REMOVE CAMSHAFT BEARING CAP (for Bank 1) 
    1. Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.
      GTY639710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolts and camshaft bearing caps in the order shown in the illustration. Immediately after removing a camshaft bearing cap, install replacement bolts and washers in the order shown in the illustration.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      NOTE:
      • Do not install the camshaft bearing caps when installing replacement bolts and washers.
      • Be sure to follow the numerical order when performing this procedure.
      • Do not allow replacement bolts or washers to contact the camshaft.
      • Do not drop replacement bolts or washers into the cylinder head sub-assembly.

      HINT: 

      • Arrange the removed parts so that they can be reinstalled in their original locations.
      • Part number for replacement bolts: 91551-F0850 (9 bolts)
      • Part number for replacement washers: 90201-12028 (18 washers)
      Fig 1: Camshaft Bearing Caps (For Bank 1) Bolts Tightening Sequence
      GTY664223Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Replacement Bolt and Washer
      *b Part Removal
      *c Replacement Bolt and Washer Installation
  33. REMOVE NO. 2 CAMSHAFT 
    1. While lifting up the camshaft timing exhaust gear assembly, remove the No. 2 chain tensioner assembly.
      GTY639693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Lift up the rear of the No. 2 camshaft so that it is at an angle.
    3. Pull the No. 2 camshaft as shown in the illustration to remove it from the camshaft timing exhaust gear assembly.
      GTY639696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE CAMSHAFT 
    1. Lift up the rear of the camshaft so that it is at an angle.
    2. Pull the camshaft as shown in the illustration to remove it from the camshaft timing gear assembly.
      GTY639695Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY (for Bank 1) 
    1. Remove the camshaft timing exhaust gear assembly.
      GTY678500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 1) 
    1. Remove the camshaft timing gear assembly and No. 2 chain sub-assembly.
      NOTE:

      Do not drop the chain sub-assembly into the gap between the engine and timing chain cover assembly.

      GTY639731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Suspend the chain sub-assembly with a string or equivalent.
      GTY639733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. DISCONNECT CHAIN SUB-ASSEMBLY (for Bank 2) 
    1. Turn the crankshaft counterclockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the timing chain cover assembly.
      GTY685350Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark (Cutout)
      *b "0" Timing Mark
    2. Remove the chain sub-assembly from the sprocket of the camshaft timing gear assembly and set it on the camshaft timing gear assembly.
      GTY639732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:

      As the camshaft may turn suddenly and pinch your fingers when the chain sub-assembly is removed, pinch the chain sub-assembly and lift it upward to remove it from the sprocket.

  38. SEPARATE NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Remove the bolt to separate the No. 3 chain tensioner assembly from the camshaft housing sub-assembly LH.
      GTY639727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2) 
    1. Use a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly and remove the camshaft timing gear bolt from the camshaft timing gear assembly.
      GTY662056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the No. 3 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
      • If the camshaft timing gear bolt has been struck or dropped, replace it.
  40. REMOVE CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2) 
    1. Use a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly and remove the camshaft timing gear bolt from the camshaft timing exhaust gear assembly.
      GTY633453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the No. 4 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
      • If the camshaft timing gear bolt has been struck or dropped, replace it.
  41. REMOVE CAMSHAFT BEARING CAP (for Bank 2) 
    1. Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.
      GTY638814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolts and camshaft bearing caps in the order shown in the illustration. Immediately after removing a camshaft bearing cap, install replacement bolts and washers in the order shown in the illustration.

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      NOTE:
      • Do not install the camshaft bearing caps when installing replacement bolts and washers.
      • Be sure to follow the numerical order when performing this procedure.
      • Do not allow replacement bolts or washers to contact the camshaft.
      • Do not drop replacement bolts or washers into the cylinder head LH.

      HINT: 

      • Arrange the removed parts so that they can be reinstalled in their original locations.
      • Part number for replacement bolts: 91551-F0850 (8 bolts)
      • Part number for replacement washers: 90201-12028 (16 washers)
      Fig 2: Camshaft Bearing Caps (For Bank 2) Bolts Tightening Sequence
      GTY643563Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Replacement Bolt and Washer
      *b Part Removal
      *c Replacement Bolt and Washer Installation
  42. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY 
    1. While lifting up the camshaft timing exhaust gear assembly, remove the No. 3 chain tensioner assembly.
      GTY638811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Lift up the rear of the No. 4 camshaft sub-assembly so that it is at an angle.
    3. Pull the No. 4 camshaft sub-assembly as shown in the illustration to remove it from the camshaft timing exhaust gear assembly.
      GTY638813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY 
    1. Lift up the rear of the No. 3 camshaft sub-assembly so that it is at an angle.
    2. Pull the No. 3 camshaft sub-assembly as shown in the illustration to remove it from the camshaft timing gear assembly.
      GTY678296Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY (for Bank 2) 
    1. Remove the camshaft timing exhaust gear assembly.
      GTY678295Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 2) 
    1. Remove the camshaft timing gear assembly and No. 2 chain sub-assembly.
      GTY638807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not drop the chain sub-assembly into the gap between the engine and timing chain cover assembly.

    2. Suspend the chain sub-assembly with a string or equivalent.
      GTY638810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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