OEM 2002 Toyota Highlander Cylinder Head Gasket

2002 Toyota Highlander Parts Questions & Experts Answers

• Q: How to replace the Cylinder Head Gasket No. 1 on 2002 Toyota Highlander?

  A: The first process to replace Cylinder Head Gasket No. 1 requires gas leakage prevention before draining coolant and engine oil. First remove the propeller shaft assembly (4WD drive type) through the use of Special Service Tool: 09325-20010 and then move on to the exhaust pipe assembly front along with manifold stay followed by exhaust manifold sub-assembly RH. Beginning the Cylinder Head Gasket No.1 replacement requires the removal of the V-bank cover together with front suspension brace sub-assembly upper center pieces and air cleaner assembly with hose and intake air surge tank. Following the removal of sub-assembly 1 fuel pipe and heater inlet water hose you should disconnect the intake manifold by removing its 9 bolts and 2 nuts and delivery pipe and injector connectors. The procedure includes disconnecting the water temperature sensor connector and ground cable to separate the radiator hose inlet and remove the water outlet through the removal of 2 bolts and 2 nuts and disconnecting the water bypass hose before removing the water outlet with its gaskets. Use Special Service Tool: 09213-54015 (91651-60855), 09330-00021 and 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05030) to remove the front wheel RH, front fender apron seal RH, V (cooler compressor to crankshaft pulley) belt No. 1, vane pump V belt, engine moving control rod, engine mounting stay No. 2 RH, generator bracket No. 2, and crankshaft pulley. Use Special Service Tool: 09960-10010 with its parts 09962-01000 and 09963-01000 to unravel the timing belt guide No. 2 together with the timing belt, timing belt idler sub-assembly No. 2, camshaft timing pulley, and transverse engine mounting bracket, timing belt guide No. 2 and timing belt No. 2 cover while using tool 09249-63010. The removal process requires an 8 mm hexagon wrench for the hexagon bolt and specified sequence of loosening 8 cylinder head bolts to successfully remove the timing belt No. 3 cover and vane pump assembly as well as ignition coil assembly, cylinder head cover sub-assembly, camshaft and No. 2 camshaft, and cylinder head sub-assembly. Measure the diameter of the tension part of the cylinder head set bolt using vernier calipers for quality control checks that guarantee it meets manufacturing criteria and has a minimum allowed outside diameter size. A new cylinder head gasket should be placed on the cylinder block surface with the R mark facing upward although no oil must appear on the contact surface and the cylinder head installation should happen quietly to protect the gasket from damage. Start by applying engine oil to the cylinder head bolts threads as well as their bolt heads then position the plate washers under the bolts before using the specified torque sequence to tighten the 8 cylinder head bolts to 54 Nm (551 kgf-cm, 40 ft. lbs.) while applying paint to the front bolt heads before retightening to 90 degrees following the specific order. The mechanic must use Special Service Tools: 09960-10010 (09962-01000, 09963-01000), 09249-63010 to install the following components: No. 2 camshaft followed by camshaft and cylinder head cover sub-assembly and ignition coil assembly with a torque of 8.0 Nm (82 kgf-cm, 71 inch lbs.) alongside vane pump assembly then timing belt No. 3 cover and camshaft timing pulley. The timing belt idler sub-assembly No. 2 requires a torque of 43 Nm (438 kgf-cm, 32 ft. lbs.), and installation process requires Special Service Tool: 09960-10010 (09962-01000, 09963-01000) for inspecting and applying the timing belt. Install the chain tensioner assembly No. 1, timing belt guide No. 2, and transverse engine mounting bracket with a torque of 28 Nm (286 kgf-cm, 21 ft. lbs.), followed by the timing belt No. 2 cover, timing belt No. 1 cover, and crankshaft pulley using Special Service Tool: 09213-54015 (91651-60855), then install generator bracket No. 2 with a torque of 28 Nm (286 kgf-cm, 21 ft. lbs.), engine mounting stay No. 2 RH, engine moving control rod, vane pump V belt, and V (cooler compressor to crankshaft pulley) belt No. 1. Install the water outlet using two new gaskets on the cylinder head and attach it to the bypass hose while securing it with 2 bolts 2 nuts and 2 plate washers using alternating torque to 15 Nm (153 kgf-cm, 11 ft. lbs.) while maintaining the seal surface unscratched. Torque the 9 bolts and 2 plate washers, 2 nuts that secure the intake manifold by evenly following the specified sequence to 15 Nm (153 kgf-cm, 11 ft. lbs.) while maintaining the same torque on the water outlet mounting bolts and nuts. Connect the fuel pipe sub-assembly No. 1, install the intake air surge tank, air cleaner assembly with hose, and vacuum hose, then install the front suspension brace sub-assembly upper center with a torque of 80 Nm (816 kgf-cm, 59 ft. lbs.), followed by the V-bank cover, exhaust manifold sub-assembly RH, and manifold stay with a torque of 34 Nm (347 kgf-cm, 25 ft. lbs.), then the exhaust pipe assembly front, propeller shaft assembly (4WD drive type), and front wheel RH with a torque of 103 Nm (1,050 kgf-cm, 76 ft. lbs.). Engine oil and coolant additions follow the examination of oil leakage and fuel drainage while testing the exhaust system for gas leakage using Special Service Tools 09843-18040, 09843-18040, 09843-18020. Idle speed assessment and compression measurement with Special Service Tool 09992-00500 and CO/HC inspection must be performed before vehicle release.