Toyota Highlander Hybrid 6 2005-06

Valve Covers

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Removal & Installation



2.4L Engines
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the right front wheel and tire assembly.
  4.  
  5. Remove the right front fender splash shield.
  6.  
  7. Remove the right front fender apron seal.
  8.  
  9. Remove engine cover sub-assembly no.1.
  10.  
  11. Remove ignition coil assembly, as outlined in the Engine Electrical Section.
  12.  
  13. Disconnect the ventilation hose and ventilation hose no. 2.
  14.  
  15. Remove cylinder head cover sub-assembly, as follows:
    1. Remove the bolt and disconnect the engine wire harness Clamp.
    2.  
    3. Remove the 8 bolts, 2 nuts, then remove the cylinder head cover and gasket.
    4.  

  16.  
  17. Thoroughly clean the gasket mating surfaces.

    Click image to see an enlarged view

    Fig. Location of the 8 bolts and 2 nuts securing the cylinder head (valve) cover-2.4L engine

  18.  

To install:

  1. Remove any old packing (fipg) material.
  2.  
  3. Apply suitable seal packing to 2 locations as shown in the illustration. Seal packing: part no. 08826-00080 or equivalent
    WARNING
    You must install the cylinder head cover within 5 minutes after applying the seal packing. Also, wait at least 2 hours after installing the cover to fill the engine with oil.



    Click image to see an enlarged view

    Fig. After removing al of the old packing material, apply suitable seal packing to the 2 locations as shown in the accompanying illustration

  4.  
  5. Install the cylinder head cover with the 8 bolts and 2 nuts. Tighten the retainers as follows:
    1. Bolt a: 8 ft. lbs. (11 Nm)
    2.  
    3. Bolt b: 10 ft. lbs. (14 Nm)
    4.  
    5. Nut: 8 ft. lbs. (11 Nm)

      Click image to see an enlarged view

      Fig. Cylinder head (valve) cover bolt tightening specifications

    6.  

  6.  
  7. Install ignition coil assembly and tighten the retainers to 80 inch lbs. (9 Nm). Refer to the Engine Electrical Section for more information.
  8.  
  9. Install the remaining components in the reverse of the removal procedure. Tighten the lug nuts to 76 ft. lbs. (103 Nm).
  10.  
  11. Wait at least 2 hours, then fill the engine with the proper type and amount of oil. Start the engine and check for leaks.
  12.  

3.3L Engine
  1. Drain the engine coolant into a suitable container.
  2.  
  3. Remove the front wiper arms.
  4.  
  5. Remove the cowl top ventilator louver sub-assembly.
  6.  
  7. Remove the windshield wiper link assembly.
  8.  
  9. Remove the cowl panel sub-assembly.
  10.  
  11. Remove the right side front fender apron seal.
  12.  
  13. Remove the front suspension upper center brace sub-assembly.
  14.  
  15. Remove the v-bank cover sub-assembly.
  16.  
  17. Remove the air cleaner cap sub-assembly.
  18.  
  19. Remove the emission control valve set.
  20.  
  21. Remove the intake air surge tank.
  22.  
  23. Remove radiator inlet hose.
  24.  
  25. Remove ignition coil, as outlined in the Engine Electrical Section.
  26.  
  27. Remove the cylinder head (valve) cover sub-assembly, as follows:
    1. Remove the 2 engine wire harness clamps.
    2.  
    3. Remove the 3 nuts and disconnect the engine wire harness.
    4.  
    5. Remove the 9 bolts and cylinder head cover.

      Click image to see an enlarged view

      Fig. Remove the 2 engine wire harness clamps (a) and the 3 nuts (b), then disconnect the engine wire harness

    6.  

  28.  
  29. Remove the cylinder head cover gasket
  30.  
  31. Remove the left cylinder head cover sub-assembly, as follows:
    1. Using an E6 Torx® -socket wrench, remove the 2 bolts and disconnect the engine wire harness protector.
    2.  
    3. Remove the 9 bolts and cylinder head cover.

      Click image to see an enlarged view

      Fig. Remove the 2 bolts, and disconnect the engine wire harness protector

    4.  

  32.  
  33. Remove the no. 2 cylinder head cover gasket.
  34.  
  35. Thoroughly clean the gasket mating surfaces. Remove all traces of oil from the contact surfaces.
  36.  

To install:

  1. Install the cylinder head (valve) cover sub-assembly, as follows:
    1. Install the gasket to the cylinder head cover.
    2.  
    3. Apply seal packing (part no. 08826-00080, or equivalent) to the cylinder head, as shown in the illustration.
      WARNING
      You must install the cylinder head cover within 3 minutes after applying seal packing. Also, do NOT start the engine for at least 2 hours after installing.

    4.  
    5. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps to a final torque of 71 inch lbs. (8 Nm).

      Click image to see an enlarged view

      Fig. Applying the seal packing-cylinder head cover sub-assembly

    6.  

  2.  
  3. Install the left cylinder head (valve) cover sub-assembly, as follows:
    1. Install the gasket to the cylinder head cover.
    2.  
    3. Apply seal packing (part no. 08826-00080, or equivalent) to the cylinder head, as shown in the illustration.
      WARNING
      You must install the cylinder head cover within 3 minutes after applying seal packing. Also, do NOT start the engine for at least 2 hours after installing.

    4.  
    5. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps to a final torque of 71 inch lbs. (8 Nm).

      Click image to see an enlarged view

      Fig. Applying the seal packing-left side cylinder head cover sub-assembly

    6.  

  4.  
  5. Install ignition coil, as outlined in the Engine Electrical Section. Tighten the retainers to 71 inch lbs. (8 Nm).
  6.  
  7. Install the inlet radiator hose.
  8.  
  9. Install the intake air surge tank.
  10.  
  11. Install the emission control valve set.
  12.  
  13. Install air cleaner cap sub-assembly.
  14.  
  15. Connect the vacuum hoses, as tagged during removal.
  16.  
  17. Install the v-bank cover sub-assembly.
  18.  
  19. Install front suspension upper center brace sub-assembly and tighten the retainers to 59 ft. lbs. (80 Nm).
  20.  
  21. Install the cowl panel sub-assembly.
  22.  
  23. Install the windshield wiper link assembly.
  24.  
  25. Install the cowl top ventilator louver sub-assembly.
  26.  
  27. Install the front wiper arms.
  28.  
  29. Fill the engine with proper type and amount of engine coolant.
  30.  
  31. After waiting a minimum of 2 hours, start the engine and inspect for engine coolant leaks.
  32.  

Hybrid
  1. Disconnect the negative battery cable.
  2.  
  3. Using a clip remover, remove the engine side cover.

    Click image to see an enlarged view

    Fig. Use a clip removal tool to remove the engine side cover

  4.  
  5. Drain the coolant and engine oil.
  6.  
  7. Remove front upper center suspension brace subassembly, as follows:
    1. Remove the 4 nuts and front suspension brace subassembly.
    2.  
    3. Install the 4 shock absorber nuts and tighten to 59 ft .lbs. (80 Nm).

      Click image to see an enlarged view

      Fig. Remove front upper center suspension brace subassembly

    4.  

  8.  
  9. Remove the air cleaner cap w/ inlet, as follows:
    1. Remove the 2 bolts, 4 clamps and air cleaner cap w/ inlet.
    2.  
    3. Remove the air cleaner filter element from the air cleaner case.
    4.  

  10.  
  11. Remove the air cleaner case w/ resonator.
  12.  
  13. Remove the emission control valve set.
  14.  
  15. Remove the intake air surge tank.
  16.  
  17. Disconnect the inlet radiator hose.
  18.  
  19. Remove the ignition coil assembly
  20.  
  21. Remove the cylinder head cover sub-assembly, as follows:
    1. Remove the 2 engine wire harness clamps.
    2.  
    3. Remove the 3 nuts and disconnect the engine wire harness.

      Click image to see an enlarged view

      Fig. Remove the 2 clamps and 3 nuts

    4.  
    5. Remove the 9 bolts and the cylinder head cover.

      Click image to see an enlarged view

      Fig. Remove the 9 bolts and the cylinder head cover

    6.  

  22.  
  23. Remove left cylinder head cover sub-assembly:
    1. Using an E6 Torx® socket wrench, remove the 2 bolts and disconnect the engine wire harness protector.

      Click image to see an enlarged view

      Fig. Use a Torx® wrench to remove the 2 bolts, then disconnect the engine wire harness protector

    2.  
    3. Put on insulating gloves, then remove the 2 engine wire harness clamps.

      Click image to see an enlarged view

      Fig. Put on insulating gloves, then remove the 2 engine wire harness clamps

    4.  
    5. Remove the 2 bolts and 2 brackets.
    6.  
    7. Remove the 9 bolts and the cylinder head cover.

      Click image to see an enlarged view

      Fig. Remove the 9 bolts and the cylinder head cover

    8.  

  24.  
  25. Thoroughly clean the gasket mating surfaces.
  26.  

To install:

  1. Install the cylinder head cover sub-assembly, as follows:
    1. Apply seal packing (part no. 08826-00080, or equivalent) to the cylinder head as shown in the illustration. Make sure all oil residue is removed from the contact surfaces prior to installing the seal packing.
      WARNING
      Install the cylinder head cover within 3 minutes after applying seal packing. Do NOT start the engine within 2 hours after installing.



      Click image to see an enlarged view

      Fig. Apply seal packing (part no. 08826-00080, or equivalent) to the cylinder head as shown

    2.  
    3. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps to a final torque of 71 inch lbs. (8 Nm).
    4.  
    5. Install the engine wire harness with the 3 nuts and 2 clamps. Tighten to 74 inch lbs. (8.4 Nm).
    6.  

  2.  
  3. Install the left cylinder head cover sub-assembly:
    1. Apply seal packing (part no. 08826-00080, or equivalent) to the cylinder head as shown in the illustration. Make sure all oil residue is removed from the contact surfaces prior to installing the seal packing.
      WARNING
      Install the cylinder head cover within 3 minutes after applying seal packing. Do NOT start the engine within 2 hours after installing.



      Click image to see an enlarged view

      Fig. Apply seal packing (part no. 08826-00080, or equivalent) to the cylinder head as shown

    2.  

  4.  
  5. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps to a final torque of 71 inch lbs. (8 Nm).
    1. Install the 2 brackets with the 2 bolts.
    2.  
    3. Install the 2 engine wire harness clamps.
      WARNING
      Wear insulating gloves.

    4.  
    5. Using an E6 Torx® socket wrench, install the engine wire harness protector with the 2 bolts. Tighten to 74 inch lbs. (8.4 Nm).
    6.  

  6.  
  7. Install the ignition coil assembly. Tighten the retainers to 71 inch lbs. (8 Nm).
  8.  
  9. Connect the radiator inlet hose.
  10.  
  11. Install the intake air surge tank.
  12.  
  13. Install the emission control valve set.
  14.  
  15. Install the air cleaner case w/ resonator.
  16.  
  17. Install the air cleaner cap w/ inlet.
  18.  
  19. Install the front upper center suspension brace subassembly.
  20.  
  21. Add the proper and amount of engine oil and coolant to the engine.
  22.  
  23. Check for engine coolant and/or oil leaks.
  24.  
  25. Install the engine side cover:
  26.  
  27. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  28.  

 
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