Toyota Highlander Service Manual: Overhaul

1. REMOVE DRAIN PLUG

(a) Remove the drain plug.

(b) Remove the O-ring.

2. ASSEMBLE SST

SST 09230-01010

(a) Install the claw to the overhaul handle, inserting it in the hole in part A as shown in the illustration.

(b) While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration.

Dimension B: 0.2 to 0.3 mm (0.008 to 0.012 in.)

NOTICE: If the stopper bolt is not adjusted, the claw may be damaged.

3. UNCAULK LOCK PLATE

Using SST, grip the handle until stopped by the stopper bolt to uncaulk the lock plate.

SST 09230-01010 (09231-01010, 09231-01030)

4. REMOVE RADIATOR TANK UPPER AND TANK LOWER

(a) Lightly tap the bracket of the radiator (or radiator hose inlet or outlet) with a plastic-faced hammer, and remove the tank.

(b) Remove the O-ring.

5. REMOVE OIL COOLER ASSY

(a) Remove the cooler pipe (b) Loosen the 2 nuts and 2 plate washers.

(c) Remove the oil cooler.

(d) Remove the 2 O-rings from the oil cooler.

6. INSTALL OIL COOLER ASSY

(a) Clean the O-ring contact surfaces of the lower tank and oil cooler.

(b) Install 2 new O-rings to the oil cooler.

(c) Install the oil cooler to the lower tank with the 2 plate washers and nuts.

Torque: 8.34 N*m (85 kgf*cm, 74 in.*lbf) (d) Install the cooler pipe in the direction indicated by the arrows in the illustration.

Torque: 14.71 N*m (150 kgf*cm, 11 ft*lbf)

7. INSPECT LOCK PLATE FOR DAMAGE

HINT:

• If the sides of the lock plate groove are deformed, reassembly of the tank will be impossible.

  Therefore, first correct any deformation with pliers or similar object.

• Water leakage will result if the bottom of the lock plate groove is damaged or dented. Repair or replace if necessary.

NOTICE: The radiator can only be recaulked 2 times. After the 2nd time, the radiator core must be replaced.

8. INSTALL RADIATOR TANK UPPER AND TANK LOWER

(a) After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it.

HINT: When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it.

(b) Install the tank without damaging the O-ring.

(c) Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and the tank.

9. ASSEMBLE SST

SST 09230-01010, 09231-14010

(a) Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration.

(b) While gripping the handle, adjust the stopper bolt so that dimension B is as shown in the illustration.

Dimension: 8.4 mm (0.331 in.)

10. CAULK LOCK PLATE

(a) Lightly press SST against the lock plate in the order shown in the illustration. After repeating this a few times, fully caulk the lock plate by gripping the handle until stopped by the stopper plate.

SST 09230-01010

HINT:

• Do not tap the areas protruding around the pipes, brackets or tank ribs.

• The points shown in the illustration and oil cooler near here (A/T) cannot be tapped with the SST. Use pliers or similar objects and be careful not to damage the core plates.

(b) Check the lock plate height (H) after completing the caulking.

Plate height (H): 7.40 to 7.80 mm (0.2913 to 0.3071 in.) If not within the specified height, adjust the stopper bolt of the handle and caulk it again.

11. INSTALL DRAIN PLUG

(a) Install a new O-ring to the drain plug.

(b) Install the drain plug.

12. INSPECT FOR WATER LEAKS

(a) Plug the inlet and outlet pipes of the radiator with SST.

SST 09230-01010
(b) Using a radiator cap tester, apply pressure to the radiator.

Test pressure: 177 kPa (1.8 kgf/cm2, 26 psi) (c) Submerge the radiator in water.

(d) Inspect for leaks.

HINT: On radiators with resin tanks, there is a clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water Before doing the water leak test, first swish the radiator in water until all air bubbles disappear.

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