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Home >> Toyota Truck >> 2002 >> Highlander 2WD V6-3.0L (1MZ-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Head Assembly >> Service and Repair >> Procedures

Procedures



CYLINDER HEAD GASKET NO.2 (1MZ-FE) REPLACEMENT
1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. DRAIN COOLANT
3. DRAIN ENGINE OIL
4. REMOVE MANIFOLD STAY NO.2
5. SEPARATE EXHAUST MANIFOLD SUB-ASSY LH
a. Remove the 2 bolts, and disconnect the exhaust manifold LH from the catalytic converter.
6. REMOVE V-BANK COVER
7. REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER
8. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
9. REMOVE INTAKE AIR SURGE TANK
10. SEPARATE FUEL PIPE SUB-ASSY NO.1
11. SEPARATE HEATER INLET WATER HOSE
12. REMOVE INTAKE MANIFOLD
13. REMOVE RADIATOR HOSE INLET
14. REMOVE WATER OUTLET
15. SEPARATE RADIATOR HOSE OUTLET
16. REMOVE WATER INLET PIPE
17. REMOVE OIL LEVEL GAGE SUB-ASSY
18. REMOVE OIL LEVEL GAGE GUIDE





19. REMOVE CYLINDER HEAD PLATE REAR
a. Disconnect the A/F sensor connector.
b. Remove the 2 bolts and cylinder head rear plate.
20. REMOVE FRONT WHEEL RH
21. REMOVE FRONT FENDER APRON SEAL RH
22. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
23. REMOVE VANE PUMP V BELT
24. REMOVE ENGINE MOVING CONTROL ROD
25. REMOVE ENGINE MOUNTING STAY NO.2 RH
26. REMOVE GENERATOR BRACKET NO.2
27. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 0995-50013 (09951-05010, 09952-05010, 09953-05010, 09954-5030)
28. REMOVE TIMING BELT NO.1 COVER
29. REMOVE TIMING BELT NO.2 COVER
30. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
31. REMOVE TIMING BELT GUIDE NO.2
32. REMOVE TIMING BELT
33. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
34. REMOVE CAMSHAFT TIMING PULLEY
SST 0996-10010 (09962-1000, 09963-01000), 09249-63010
35. REMOVE TIMING BELT NO.3 COVER
36. REMOVE IGNITION COIL ASSY
37. REMOVE CYLINDER HEAD COVER SUB-ASSY LH
38. REMOVE NO.3 CAMSHAFT SUB-ASSY
39. REMOVE NO.4 CAMSHAFT SUB-ASSY
40. REMOVE CYLINDER HEAD LH





a. Using an 8 mm hexagon wrench, remove the hexagon bolt.





b. Uniformly loosen the 8 cylinder head bolts, in several passes, in the sequence shown. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
- Be careful no to drop washers into the cylinder head.
- Head warpage or cracking could result from removing bolts in an incorrect order.

41. REMOVE CYLINDER HEAD GASKET NO.2
42. INSPECT CYLINDER HEAD SET BOLT





43. INSTALL CYLINDER HEAD GASKET NO.2
a. Place a new cylinder head gasket on the cylinder block surface with the L mark upward.

NOTICE:
- Remove any oil from the contact surface.
- Be careful of the installation direction.
- Place the cylinder head quietly in order not to damage the gasket at the bottom part of the head.

44. INSTALL CYLINDER HEAD LH

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

a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Install the plate washer to the cylinder head bolt.





c. Install and uniformly tighten the 8 cylinder head bolts, in several passes, in the sequence shown.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)





d. Mark the front side of each cylinder head bolt head with paint.
e. Retighten the cylinder head bolts by 90° in the sequence shown.
f. Check that the painted mark is now at a 90° angle to the front.





g. Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
45. INSTALL NO.4 CAMSHAFT SUB-ASSY
46. INSTALL NO.3 CAMSHAFT SUB-ASSY
47. INSTALL CYLINDER HEAD COVER SUB-ASSY LH
48. INSTALL IGNITION COIL ASSY
Torque:8.0 Nm (82 kgf-cm, 71 inch lbs.)
49. INSTALL TIMING BELT NO.3 COVER
50. INSTALL CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 0996-01000), 09249-63010
51. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
52. INSPECT TIMING BELT
53. INSTALL TIMING BELT
SST 09960-10010 (09962-01000, 09963-01000)
54. INSTALL CHAIN TENSIONER ASSY NO.1
55. INSTALL TIMING BELT GUIDE NO.2
56. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
57. INSTALL TIMING BELT NO.2 COVER
58. INSTALL TIMING BELT NO.1 COVER
59. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
60. INSTALL GENERATOR BRACKET NO.2
Torque:28 Nm (286 kgf-cm, 21 ft. lbs.)
61. INSTALL ENGINE MOUNTING STAY NO.2 RH)
62. INSTALL ENGINE MOVING CONTROL ROD
63. INSTALL VANE PUMP V BELT
64. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
65. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE)





66. INSTALL CYLINDER HEAD PLATE REAR
a. Install the cylinder head rear plate with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
67. INSTALL OIL LEVEL GAGE GUIDE
68. INSTALL WATER INLET PIPE
69. INSTALL WATER OUTLET
70. INSTALL INTAKE MANIFOLD
71. CONNECT FUEL PIPE SUB-ASSY NO.1
72. INSTALL INTAKE AIR SURGE TANK
73. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
74. CONNECT VACUUM HOSE
75. INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
76. INSTALL V-BANK COVER
77. INSTALL EXHAUST MANIFOLD SUB-ASSY LH
a. Install a new gasket and the exhaust manifold to the catalytic converter.
Torque: 56 Nm (571 kgf-cm, 41 ft. lbs.)
78. INSTALL MANIFOLD STAY NO.2
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
79. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
80. ADD ENGINE OIL
81. ADD COOLANT
82. INSPECT OIL LEAK
83. INSPECT FOR ENGINE COOLANT LEAKS
84. INSPECT FOR FUEL LEAKS
85. CHECK FOR EXHAUST GAS LEAK
86. INSPECT IGNITION TIMING
SST 09843-18040, 09843-18020
87. INSPECT ENGINE IDLE SPEED)
SST 09843-18040
88. INSPECT COMPRESSION
SST 09992-00500
89. INSPECT CO/HC
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