Toyota Highlander 6 2001-06

Oil Pan

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Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Engine undercover
     
    Engine oil
     
    Oil pan bolts, nuts and pan
     

  4.  
  5. Installation is the reverse of removal. Torque the 12 bolts and 2 nuts to 80 inch lbs. (9 Nm).

    Click image to see an enlarged view

    Fig. Oil pan, pump and related parts-2.4L Highlander

  6.  

3.0L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Right front wheel
     
    Fender apron seal
     
    Engine undercover
     

  4.  
  5. Drain the engine oil from the engine.
  6.  
  7. Remove or disconnect the following:

    Front exhaust pipe
     
    Front exhaust pipe bracket from the No. 1 oil pan
     
    Flywheel housing undercover
     
    10 bolts and 2 nuts to the No. 2 oil pan
     

  8.  
  9. Insert the blade of the Oil Pan Seal Cutting tool 09032-00100 between the No. 1 and No. 2 oil pans. Clean the surfaces of the oil pans.
  10.  
  11. Remove or disconnect the following:

    3 oil strainer nuts and gasket
     

  12.  
  13. Remove the No. 1 oil pan, as follows:
    NOTE
    Make a note of the position of the each bolt. When replacing the bolts into the oil pan, place each bolt in the position from which it was removed.


    NOTE
    Be careful not to damage the contact surfaces.



    2 bolts and the flywheel housing undercover
     
    17 bolts and 2 nuts to the No. 1 oil pan
     



    Oil pan, by prying the portions between the cylinder block and the oil pan
     



    Baffle plate from the No. 1 oil pan
     

  14.  

To install:

  1. Clean all mating surfaces of the oil pans.
  2.  
  3. Install the baffle plate to the No. 1 oil pan and tighten to 69 inch lbs. (8 Nm).
  4.  
  5. Install the No. 1 oil pan, as follows:
    1. Using a non residue solvent, clean both sealing surfaces to the oil pan.
    2.  
    3. Apply liquid sealant to the oil pan and engine block.
    4.  
    5. Install the oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
    6.  
    7. Tighten the No. 1 oil pan bolts, as follows:

      10mm head bolt: 69 inch lbs. (8 Nm)
       
      12mm head bolt: 14 ft. lbs. (20 Nm)
       
      14mm head bolt: 27 ft. lbs. (37 Nm)
       

    8.  
    9. Install the flywheel housing undercover with the 2 bolts. Tighten the bolts to 69 inch lbs. (8 Nm).
    10.  

  6.  
  7. Install the oil strainer with the 3 nuts. Tighten the nuts to 69 inch lbs. (8 Nm).
  8.  
  9. Install the No. 2 oil pan, as follows:
    1. Using a non residue solvent, clean both sealing surfaces to the oil pan.
    2.  
    3. Apply liquid sealant to the oil pan and engine block.
    4.  
    5. Install the No. 2 oil pan with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Tighten the bolts to 69 inch lbs. (8 Nm).
    6.  

  10.  
  11. Install or connect the following:

    Flywheel housing undercover
     
    Front exhaust pipe bracket to the No. 1 oil pan. Tighten the bolts to 15 ft. lbs. (21 Nm).
     

  12.  
  13. Install the front exhaust pipe, as follows:

    Temporarily install the 3 new gaskets and the front exhaust pipe with the 2 bolts and 6 nuts
     
    Tighten the 4 exhaust manifolds-to-front exhaust pipe nuts to 46 ft. lbs. (62 Nm).
     
    Tighten the both front exhaust pipe-to-center exhaust pipe nuts/bolts to 41 ft. lbs. (56 Nm).
     
    Bracket. Tighten both bolts to 14 ft. lbs. (19 Nm).
     
    Support stay. Tighten both bolts to 22 ft. lbs. (29 Nm).
     

  14.  
  15. Install or connect the following:

    Engine undercover
     
    Right fender apron seal
     
    Right front wheel
     

  16.  
  17. Fill the engine with oil.
  18.  
  19. Start the engine and check for leaks.
  20.  

3.3L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Right front wheel
     
    Fender apron seal
     
    Engine undercover
     

  4.  
  5. Drain the engine oil from the engine.
  6.  
  7. Remove or disconnect the following:

    Front exhaust pipe
     
    Front exhaust pipe bracket from the No. 1 oil pan
     
    Flywheel housing undercover
     
    10 bolts and 2 nuts to the No. 2 oil pan
     

  8.  
  9. Insert the blade of the Oil Pan Seal Cutting tool 09032-00100 between the No. 1 and No. 2 oil pans. Clean the surfaces of the oil pans.
  10.  
  11. Remove or disconnect the following:

    3 oil strainer nuts and gasket
     

  12.  
  13. Remove the No. 1 oil pan, as follows:
    NOTE
    Make a note of the position of the each bolt. When replacing the bolts into the oil pan, place each bolt in the position from which it was removed.


    NOTE
    Be careful not to damage the contact surfaces.



    2 bolts and the flywheel housing undercover
     
    17 bolts and 2 nuts to the No. 1 oil pan
     



    Oil pan, by prying the portions between the cylinder block and the oil pan
     



    Baffle plate from the No. 1 oil pan

    Click image to see an enlarged view

    Fig. Oil pan, pump and related parts-3.3L engine shown

     

  14.  

To install:

  1. Clean all mating surfaces of the oil pans.
  2.  
  3. Install the baffle plate to the No. 1 oil pan and tighten to 69 inch lbs. (8 Nm).
  4.  
  5. Install the No. 1 oil pan, as follows:
    1. Using a non residue solvent, clean both sealing surfaces to the oil pan.
    2.  
    3. Apply liquid sealant to the oil pan and engine block.
    4.  
    5. Install the oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
    6.  
    7. Tighten the No. 1 oil pan bolts, as follows:

      10mm head bolt: 69 inch lbs. (8 Nm)
       
      12mm head bolt: 14 ft. lbs. (20 Nm)
       
      14mm head bolt: 27 ft. lbs. (37 Nm)
       

    8.  
    9. Install the flywheel housing undercover with the 2 bolts. Tighten the bolts to 69 inch lbs. (8 Nm).
    10.  

  6.  
  7. Install the oil strainer with the 3 nuts. Tighten the nuts to 69 inch lbs. (8 Nm).
  8.  
  9. Install the No. 2 oil pan, as follows:
    1. Using a non residue solvent, clean both sealing surfaces to the oil pan.
    2.  
    3. Apply liquid sealant to the oil pan and engine block.
    4.  
    5. Install the No. 2 oil pan with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes. Tighten the bolts to 69 inch lbs. (8 Nm).
    6.  

  10.  
  11. Install or connect the following:

    Flywheel housing undercover
     
    Front exhaust pipe bracket to the No. 1 oil pan. Tighten the bolts to 15 ft. lbs. (21 Nm).
     

  12.  
  13. Install the front exhaust pipe, as follows:

    Temporarily install the 3 new gaskets and the front exhaust pipe with the 2 bolts and 6 nuts
     
    Tighten the 4 exhaust manifolds-to-front exhaust pipe nuts to 46 ft. lbs. (62 Nm).
     
    Tighten the both front exhaust pipe-to-center exhaust pipe nuts/bolts to 41 ft. lbs. (56 Nm).
     
    Bracket. Tighten both bolts to 14 ft. lbs. (19 Nm).
     
    Support stay. Tighten both bolts to 22 ft. lbs. (29 Nm).
     

  14.  
  15. Install or connect the following:

    Engine undercover
     
    Right fender apron seal
     
    Right front wheel
     

  16.  
  17. Fill the engine with oil.
  18.  
  19. Start the engine and check for leaks.
  20.  

Hybrid
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Engine/transaxle assembly from the vehicle
     
    Right-hand exhaust manifold
     
    Transaxle mass damper
     
    Front frame assembly
     
    Halfshafts
     
    Flywheel housing undercover
     
    Front engine mounting bracket
     
    Transaxle assembly from the engine
     
    Transmission input damper assembly
     
    Flywheel
     

  4.  
  5. Install the engine to a suitable engine stand.
  6.  
  7. Remove or disconnect the following:

    Remaining exhaust manifold heat shields
     
    Right-hand engine mounting bracket
     
    Compressor mounting bracket
     
    Crankshaft pulley
     
    Timing belt
     
    Timing belt idler
     
    Crankshaft timing pulley
     
    Oil level gauge assembly
     

  8.  
  9. Remove the lower oil pan as follows:
    1. Remove the mounting bolts and nuts
    2.  
    3. Using Special Tool 09032-00100 or suitable seal cutter, cut the sealant between the upper and lower oil pans.
    4.  
    5. Remove the lower oil pan.

      Click image to see an enlarged view

      Fig. Use a suitable tool to cut the sealant between the oil pans.

    6.  

  10.  
  11. Remove the oil strainer and gasket.
  12.  
  13. Remove the upper oil pan as follows:
    1. Uniformly loosen and remove the mounting bolts.
    2.  
    3. Using a suitable pry tool, pry the upper oil pan from the cylinder block.
    4.  

  14.  

To install:

  1. Remove any old sealant from the mating surface of the oil pans.
  2.  
  3. Install the upper oil pan as follows:
    1. Apply a 0.12-0.16 inch (3-4 mm) wide continuous bead of sealant to the mating surface as shown in the illustration.
    2.  
    3. Install the upper oil pan mounting bolts and tighten in several steps. Tighten bolts -A- to 71 inch lbs. (8 Nm) and bolts -B- to 14 ft. lbs. (20 Nm).

      Click image to see an enlarged view

      Fig. Apply the sealant to the upper oil pan as shown.



      Click image to see an enlarged view

      Fig. Upper oil pan bolt locations

    4.  

  4.  
  5. Install the oil strainer with a new gasket. Tighten to 71 inch lbs. (8 Nm).
  6.  
  7. Install the lower oil pan as follows:
    1. Apply a 0.16-0.20 inch (4-5 mm) wide continuous bead of sealant to the mating surface as shown in the illustration.
    2.  
    3. Install the lower oil pan mounting bolts and nuts. Tighten to 71 inch lbs. (8 Nm).

      Click image to see an enlarged view

      Fig. Apply sealant to the lower oil pan as shown.

    4.  

  8.  
  9. The remainder of the installation is the reverse order of removal.
  10.  
  11. Refill the engine with oil to the correct level.
  12.  
  13. Start the engine and check for leaks.
  14.  
  15. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  16.  

 
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