Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSTOYOTA2002HIGHLANDER 4WD L4-2.4L (2AZ-FE)REPAIR AND DIAGNOSISENGINE, COOLING AND EXHAUSTCOOLING SYSTEMRADIATOR CAPTESTING AND INSPECTION
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)
Radiator Cap: Testing and Inspection
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)SECTION Testing and Inspection
INSPECTION
RADIATOR CAP SUB-ASSY
NOTICE:
^ If the reservoir cap has contaminations, always rinse it with water.
^ Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water.
a. Using a radiator cap tester, slowly pump the tester and check that air is coming from the vacuum valve.
Pump speed: 1 push/(3 seconds or more)
NOTICE: Push the pump at a constant speed. If air is not coming from the vacuum valve, replace the reservoir cap.
b. Pump the tester and measure the relief valve opening pressure.
Pump speed: 1 push within 1 second
NOTICE: This pump speed is for the first pump only (in order to close the vacuum valve). After this, the pump speed can be reduced.
Standard opening pressure: 93 - 122 kPa (0.95 - 1.25 kgf/cm2, 13.4 - 17.6 psi)
Minimum opening pressure: 78 kPa (0.8 kgf/cm2, 11.2 psi)
HINT: Use the tester's maximum reading as the opening pressure. If the opening pressure is less than minimum, replace the reservoir cap.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.