Toyota Highlander 6 2001-06

Cylinder Head

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Removal & Installation



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

    Coolant
     
    Engine oil
     
    Exhaust pipes
     
    Exhaust manifold
     
    Camshaft cover
     
    Upper center front suspension brace
     
    Air cleaner
     
    Intake air surge tank
     
    Fuel rail
     
    Heater hoses
     
    Intake manifold
     
    Radiator hose
     
    Water outlet
     
    Right front wheel
     
    Right fender apron seal
     
    Accessory drive belts
     
    Engine roll stopper rod
     
    Right engine mount
     
    Alternator and brackets
     
    Crankshaft pulley
     
    Timing belt covers
     
    Transverse engine mounting bracket
     
    Timing belt
     
    Timing belt tensioner
     
    Power steering pump
     
    Ignition coil pack
     
    Camshafts
     
    The hexagonal bolt, using an 8mm hex wrench, then the 8 head bolts

    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-3.0L engine

     
    Cylinder head
     

  4.  
  5. Installation is the reverse of removal. Measure the head bolts. The minimum diameter of the stretch portion of each bolt should be at least 8.75mm (0.3775 in.). Replace any bolt that does not measure up. The head gasket is installed with the R mark upwards. Install the 8 head bolts first, tightened in sequence, in 2 equal steps, to 40 ft. lbs. (54 Nm). Then tighten each an additional 90 degrees. Finally, install the hex bolt, torque to 14 ft. lbs. (19 Nm).

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-3.0L engine

  6.  

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

    Wiper and blade assembly
     
    Top cowl seal and panel
     
    Window washer hoses from the ventilator louvers
     
    Left and right ventilator louvers
     
    Heater air duct
     

  4.  
  5. Relieve the fuel pressure.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Wait at least 90 seconds from the time the negative battery was disconnected to start work.



    Turn the ignition key to the OFF position
     
    Negative battery cable
     

  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following:

    Accelerator and throttle cables, if equipped with an automatic transaxle
     
    Air cleaner cover, air flow meter and the air duct
     
    Front upper suspension brace
     
    Cruise control actuator and bracket, if equipped
     
    2 engine ground straps
     
    Right engine mounting support
     
    Radiator hoses
     
    2 heater hoses
     
    Fuel feed and return lines from the fuel rail assembly
     
    Pressure hose from the hydraulic motor
     
    V-bank cover
     

  12.  
  13. Disconnect the following vacuum hoses:

    Fuel pressure control Vacuum Switching Valve (VSV)
     
    Fuel pressure regulator
     
    Cylinder head rear plate
     
    Intake air control valve VSV
     
    Exhaust Gas Recirculation (EGR) vacuum modulator
     
    EGR valve
     

  14.  
  15. Disconnect the following wiring and hoses:

    Intake air control valve
     
    Fuel pressure regulator
     
    EGR VSV
     

  16.  
  17. Remove the 2 nuts and the emission control valve set.
  18.  
  19. Disconnect the following hoses;

    Brake booster vacuum hose
     
    PCV hose
     
    Intake air control valve vacuum hose
     

  20.  
  21. Remove or disconnect the following:

    Data Link Connector (DLC) from the mounting bracket
     
    2 ground straps from the intake chamber
     
    Hydraulic motor pressure hose from the intake chamber
     
    Right Oxygen (O 2 ) sensor connector from the power steering pressure tube
     
    2 nuts and the power steering pressure tube from the intake chamber
     
    Both power steering air hoses
     
    Engine hanger and the intake chamber support
     
    EGR pipe and gaskets
     

  22.  
  23. Disconnect the following wiring:

    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) valve connector
     
    EGR gas temperature connector
     
    Air conditioning idle up connector
     

  24.  
  25. Disconnect the following vacuum hoses:

    2 vacuum hoses from the Thermal Vacuum Valve (TVV)
     
    Vacuum hose from the cylinder head rear plate
     
    Vacuum hose from the charcoal canister
     

  26.  
  27. Remove or disconnect the following:

    Air assist hose and the 2 water bypass hoses
     
    Air intake chamber
     
    Left engine wiring harness and move it aside
     
    Wiring harness from the rear of the engine
     
    Right engine wiring harness and move it aside
     
    Ignition coils and move them aside
     
    Timing belt
     
    Camshaft pulleys and the timing belt rear cover
     
    Cylinder head rear plate
     
    Water inlet pipe
     
    Air assist hose and vacuum hose
     
    Intake manifold and fuel rail assembly
     
    Water outlet
     
    EGR pipe from the right exhaust manifold
     
    Front exhaust pipe and exhaust manifolds
     
    Dipstick assembly and the power steering pump bracket
     
    Valve covers and the Camshaft Position (CMP) sensor
     
    Camshafts
     

  28.  
  29. Be sure the engine is at/or near ambient temperature and remove the 2 (1 on each head) 8mm recessed hex bolts. Loosen and remove the 8 head bolts evenly, in 3 passes, in the reverse order of the installation sequence. Carefully lift the head from the engine; if necessary to pry the head loose, take great care not to damage the mating surfaces. Place the head on wood blocks in a clean work area.
    NOTE
    If the cylinder head bolts are loosened out of sequence, warpage or cracking could result.



    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-3.3L engine



    Click image to see an enlarged view

    Fig. Right cylinder head and related parts-3.3L engine



    Click image to see an enlarged view

    Fig. Left cylinder head and related parts-3.3L engine

  30.  
  31. Remove the cylinder head gasket. With a gasket scraper, carefully remove all the old gasket material from the cylinder head and engine block surfaces.
  32.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-3.3L engine

  1. Place the new cylinder head gasket onto the cylinder block.
  2.  
  3. Install the cylinder head, in sequence, using several steps, as follows:
    NOTE
    If any bolt does not meet the torque, replace it.


    NOTE
    The paint mark applied to the bolt in the 9 o-clock position and should now be in the 12 o-clock position.



    Cylinder head onto the gasket
     
    Cylinder head bolts lubricated with clean engine oil
     
    Tighten the bolts in sequence in 3 steps to 40 ft. lbs. (54 Nm).
     



    Mark the forward edge of each bolt with paint, then tighten each bolt, in proper sequence, an additional 90 degrees.
     
    Check that each painted mark is now at a 90 degrees angle to the front
     



    Remaining 8mm bolts, lubricated with engine oil. Tighten both bolts to 13 ft. lbs. (18 Nm).
     

  4.  
  5. Install the camshafts.
  6.  
  7. Check and adjust the valves.
  8.  
  9. Apply sealant to the cylinder heads where the camshaft supports meet the cylinder heads.
  10.  
  11. Install or connect the following:

    Cylinder head covers, using new gaskets
     
    Dipstick and power steering pump bracket
     
    Exhaust manifolds. Tighten the nuts to 36 ft. lbs. (49 Nm).
     
    EGR pipe to the right exhaust manifold
     
    Water outlet
     
    Intake manifold and the fuel rail assembly. Tighten the intake manifold nuts/bolts to 11 ft. lbs. (15 Nm).
     
    Air assist hose and the 2 water bypass hoses
     
    Water inlet pipe and cylinder head rear plate
     
    Timing belt rear cover and camshaft pulleys
     
    Timing belt
     
    Spark plugs and ignition coils
     
    Right engine wiring harness
     
    Wiring harness to the rear of the engine
     
    Left engine wiring harness
     
    Air intake chamber
     
    EGR pipe, using new gaskets
     

  12.  
  13. Connect the following vacuum hoses:

    The 2 TVV vacuum hoses
     
    The vacuum hose to the rear cylinder head plate
     
    Charcoal canister vacuum hose
     

  14.  
  15. Connect the following electrical wiring:

    TP sensor connector
     
    IAC valve connector
     
    EGR gas temperature connector
     
    Air conditioning idle up connector
     

  16.  
  17. Install or connect the following:

    Engine hanger and the intake chamber support
     
    Both power steering air hoses
     
    Power steering pressure tube to the intake chamber
     
    O 2 sensor connector to the pressure tube.
     
    Both ground straps, to the intake chamber
     
    DLC to the bracket
     

  18.  
  19. Connect the following hoses:

    Power brake booster vacuum hose
     
    PCV hose
     
    IAC valve vacuum hose
     

  20.  
  21. Install or connect the following:

    Emission control valve set and related vacuum hoses and connectors
     
    V-bank cover
     
    Pressure hose to the hydraulic motor
     
    Fuel lines to the fuel rail assembly
     
    Heater and radiator hoses
     
    Right engine mounting support
     
    both engine ground straps
     
    Upper front suspension brace, if removed. Tighten the nuts to 59 ft. lbs. (80 Nm).
     
    Cruise control actuator and bracket
     
    Air cleaner, air flow meter and air duct assembly
     
    Accelerator and throttle cables
     

  22.  
  23. Fill the cooling system.
  24.  
  25. Install or connect the following:

    Negative battery cable
     
    Heater air duct
     
    Left and right ventilator louvers
     
    Window washer hoses from the ventilator louvers
     
    Top cowl seal and panel
     
    Wiper and blade assembly
     

  26.  
  27. Start the engine and check for leaks.
  28.  
  29. Bleed the air from the cooling system.
  30.  
  31. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation.
  32.  
  33. Recheck the coolant and engine oil levels.
  34.  

Hybrid
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the coolant from the engine radiator and hybrid transaxle.
  8.  
  9. Remove the service plug grip, found underneath the Battery Service cover on the rear seat. Wait 5 minutes to discharge the high voltage capacitor.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Right-hand front wheel
     
    Engine splash shields
     
    Right-hand front fender apron seal
     
    Wiper and blade assembly
     
    Top cowl ventilator louver assembly
     
    Wiper motor and link assembly
     
    Battery and battery tray
     
    Air intake assembly
     
    Converter with Inverter assembly
     
    Emission control valve set
     
    Intake air surge tank
     
    Fuel supply hose
     
    Heater inlet hose
     
    Intake manifold
     
    Radiator hoses
     
    Water outlet from the cylinder heads
     
    Brake master cylinder reservoir
     
    Air cleaner bracket
     
    Engine moving control rod
     
    Right-hand No.2 engine mounting stay
     
    Crankshaft pulley
     
    Timing belt No.1 and No.2 covers
     
    Right-hand engine mounting bracket
     
    Timing belt guide No.2
     
    Timing belt
     
    Timing belt No.2 idler
     
    Camshaft timing pulley
     
    Timing belt No.3 cover
     
    Front exhaust pipe assembly
     
    Exhaust manifold heat insulator
     
    Exhaust manifold stay
     
    Right-hand exhaust manifold and gasket
     
    Ignition coil
     
    Right-hand cylinder head cover
     
    Camshaft
     
    VVT sensor connector
     
    Camshaft timing oil control valve connecter
     

  12.  
  13. Loosen the right-hand cylinder head bolts in several steps in the sequence shown.

    Click image to see an enlarged view

    Fig. Right-hand cylinder head loosening sequence

  14.  
  15. Remove the cylinder head bolts and plate washers.
  16.  
  17. Remove the right-hand cylinder head and gasket.
  18.  
  19. Remove the manifold converter No.3 insulator.
  20.  
  21. Remove the exhaust manifold No.2 heat insulator.
  22.  
  23. Separate the cooling fan ECU and hang securely with mechanic-s wire.
  24.  
  25. Remove or disconnect the following:

    Left-hand exhaust manifold
     
    Oil level gauge guide
     
    Water inlet pipe
     
    Left-hand cylinder head cover
     
    Camshaft
     

  26.  
  27. Loosen the right-hand cylinder head bolts in several steps in the sequence shown.

    Click image to see an enlarged view

    Fig. Left-hand cylinder head loosening sequence

  28.  
  29. Remove the cylinder head bolts and plate washers.
  30.  
  31. Remove the left-hand cylinder head and gasket.
  32.  

To install:

  1. Install the left-hand cylinder head with a new gasket. Tighten the cylinder head bolts as follows:
    1. Step 1: Tighten the 8 cylinder head bolts to 40 ft. lbs. (54 Nm)
    2.  
    3. Step 2: Tighten each bolt 90°
    4.  
    5. Step 3: Tighten each bolt an additional 90°
    6.  
    7. Step 4: Tighten the single 8mm hexagon bolt to 14 ft. lbs. (19 Nm)

      Click image to see an enlarged view

      Fig. Left-hand cylinder head tightening sequence



      Click image to see an enlarged view

      Fig. 8mm hexagon bolt on the cylinder head

    8.  

  2.  
  3. Install or connect the following:

    Camshaft
     
    Left-hand cylinder head cover. Tighten to 71 inch lbs. (8 Nm).
     
    Water inlet pipe
     
    Oil level gauge guide. Tighten to 71 inch lbs. (8 Nm).
     
    Exhaust manifold No. 2 converter
     
    Cooling fan ECU
     
    Exhaust manifold No.2 heat insulator
     
    Manifold converter No.2 insulator
     

  4.  
  5. Install the right cylinder head with a new gasket. Tighten the cylinder head bolts as follows:
    1. Step 1: Tighten the 8 cylinder head bolts to 40 ft. lbs. (54 Nm)
    2.  
    3. Step 2: Tighten each bolt 90°
    4.  
    5. Step 3: Tighten each bolt an additional 90°
    6.  
    7. Step 4: Tighten the single 8mm hexagon bolt to 14 ft. lbs. (19 Nm)

      Click image to see an enlarged view

      Fig. Right-hand cylinder head tightening sequence

    8.  

  6.  
  7. The remainder of installation is the reverse order of removal.
  8.  
  9. Refill the engine oil to the correct level.
  10.  
  11. Refill the coolant to the engine radiator and hybrid transaxle to the correct level.
  12.  
  13. Replace the service plug grip.
  14.  
  15. Start the engine and check for leaks.
  16.  
  17. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  18.  

 
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