Toyota Highlander Service Manual: Cylinder head gasket (2AZ-FE)

REPLACEMENT

1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 11-1 )

2. REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)

3. DRAIN COOLANT (See page 16-6 )

4. DRAIN TRANSFER OIL (4WD TYPE)

5. DISCONNECT RADIATOR HOSE OUTLET

6. DISCONNECT UNION TO CONNECTOR TUBE HOSE

7. DISCONNECT HEATOR INLET WATER HOSE

8. DISCONNECT FUEL TUBE SUB-ASSY (See page 11-10 )

9. SEPARATE FRONT DRIVE SHAFT ASSY RH (4WD TYPE) (See page 30-21 )

10. SEPARATE ENGINE MOUNTING INSULATOR ASSY RR (4WD TYPE)

(a) Remove the 2 bolts and disconnect the engine mounting insulator.

11. REMOVE ENGINE MOUNTING BRACKET RR (4WD TYPE) (See page 14-24 )

12. REMOVE INTAKE MANIFOLD (See page 14-24 )

13. DISCONNECT ENGINE WIRE

14. REMOVE INTAKE MANIFOLD INSULATOR NO.1

15. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1

16. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY (See page 14-24 )

17. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY

18. REMOVE CHAIN SUB-ASSY (See page 14-68 )

19. REMOVE NO.2 CAMSHAFT (See page 14-41 )

20. REMOVE CAMSHAFT (See page 14-41 )

21. REMOVE CAMSHAFT BEARING NO.2

22. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY

23. REMOVE CYLINDER HEAD SUB-ASSY

(a) Using a 10 mm Bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

NOTICE:

• Be careful not to drop washers into the cylinder head.
• Head warpage or cracking could result from removing bolts in an incorrect order.

24. REMOVE CYLINDER HEAD GASKET

25. INSPECT CYLINDER HEAD SET BOLT (See page 14-41 )

26. INSTALL CYLINDER HEAD GASKET

(a) Place a new gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:

• Remove any oil from contact surface.
• Be careful of the installation direction.
• To avoid damage to the gasket, place the cylinder head on the gasket carefully.

27. INSTALL CYLINDER HEAD SUB-ASSY

HINT: The cylinder head bolts are tightened in 2 progressive steps.

(a) Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers.

(b) Install the bolts and plate washers to the cylinder head.

NOTICE: Do not drop the washers into the cylinder head.

(c) Using a 10 mm bi-hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration.

Torque: 79 NVm (806 kgfVcm, 58 ftVlbf)

(d) Mark the front side of the cylinder head bolt with paint.

(e) Retighten the cylinder head bolts 90 in the sequence shown in the illustration.

(f) Check that the painted mark is now at a 90 angle to the front.

28. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)

29. INSTALL CAMSHAFT BEARING NO.2

30. INSTALL CAMSHAFT (See page 14-41 )

31. INSTALL NO.2 CAMSHAFT (See page 14-41 )

32. INSTALL CHAIN SUB-ASSY (See page 14-68 )

33. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY

34. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY

(a) Install a new gasket and the exhaust manifold convert with the 5 nuts. Uniformly tighten the nuts in the sequence shown in the illustration.

Torque: 37 NVm (337 kgfVcm, 27 ftVlbf)

(b) Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts.

Torque: 44 NVm (449 kgfVcm, 32 ftVlbf)

35. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 Torque: 12 NVm (122 kgfVcm, 9 ftVlbf)

36. INSTALL INTAKE MANIFOLD INSULATOR NO.1

37. INSTALL ENGINE WIRE

38. INSTALL INTAKE MANIFOLD (See page 14-24 )

39. INSTALL ENGINE MOUNTING BRACKET RR (4WD TYPE) (See page 14-24 )

40. INSTALL ENGINE MOUNTING INSULATOR ASSY RR (4WD TYPE)

(a) Install the mounting insulator with bolts.

Torque: 75 NVm (765 kgfVcm, 55 ftVlbf)

41. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD TYPE) (See page 30-21 )

42. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)

43. CONNECT FUEL TUBE SUB-ASSY (See page 11-10 )

44. INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER Torque: 80 NVm (816 kgfVcm, 59 ftVlbf)

45. ADD ENGINE OIL

46. ADD COOLANT (see page 16-6 )

47. ADD TRANSFER OIL (4WD TYPE)

(a) Install a new gasket and the filler plug.

Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)

48. CHECK FOR OIL LEAKS

49. CHECK FOR ENGINE COOLANT LEAKS (See page 16-6 )

50. INSPECT FOR FUEL LEAKS (See page 11-4 )

51. CHECK IDLE SPEED AND IGNITION TIMING (See page 14-1 )

52. INSPECT CO/HC (See page 14-1 )

53. CHECK ABS SPEED SENSOR SIGNAL

54. INSPECT FRONT WHEEL ALIGNMENT (See page 26-7 )

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