TOYOTA HIGHLANDER 2001 Service Repair Manual

Engine
Front
A52462
A93972
Disconnect
HookPin
Turn
A93973
Plunger
Push
Turn
14-66
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2559 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(b) Install a new gasket and the chain tensioner with the 2
nuts.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
NOTICE:
If the hook is released while inserting, apply the hook
again, and insert the chain tensioner.
(c) Turn the crankshaft counterclockwise and check that the
plunger knock pin is disconnected from the hook.
(d) Turn the crankshaft clockwise and check that the slipper
is pushed by the plunger.
87. INSPECT VALVE CLEARANCE (See page 14-6)
88. ADJUST VALVE CLEARANCE (See page 14-6)
89. INSTALL CYLINDER HEAD COVER GASKET
(a) Install the gasket to the cylinder head cover.

A94205
Seal Packing
Seal Packing
A94204NutNut AA A A
B
AABB
SST
A36541
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-67
2560 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
90. INSTALL CYLINDER HEAD COVER SUB-ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to the 2 locations shown in the illustra-
tion.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 5 minutes after
applying seal packing.

Do not apply engine oil for at least 2 hours after instal-
ling.
(c) Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque:
11 NVm (112 kgfVcm, 8 ftVlbf) for nut
11 NVm (112 kgfVcm, 8 ftVlbf) for bolt A
14 NVm (143 kgfVcm, 10 ftVlbf) for bolt B
91. INSTALL SPARK PLUG
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
92. INSTALL VENTILATION VALVE SUB-ASSY
(a) Apply adhesive on the threads of the ventilation valve.
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent
93. INSTALL OIL FILLER CAP SUB-ASSY
94. INSTALL OIL FILTER UNION
(a) Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)
95. INSTALL OIL FILTER SUB-ASSY
(a) Check and clean the oil filter installation surface.
(b) Apply clean engine oil to the gasket of a new oil filter.
(c) Lightly screw the oil filter into place, and tighten it until the
gasket contacts the seat.
(d) Using SST, tighten it an additional 3/4 turn.
SST 09228-06501

3100U-07
C50328C83630SST
C50353C83631
8.7 to 9.3 mm
(0.3425 to 0.3661 in.)SST
- TRANSFERTRANSFER CASE OIL SEAL (4WD)
31-7
3085 Author
: Date
:
TRANSFER CASE OIL SEAL (4WD)
REPLACEMENT
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE)
(SEE PAGE 14-149)
2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE)
(SEE PAGE 14-24)
3. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (2AZ-FE ENGINE TYPE)
(SEE PAGE 31-9)
4. REMOVE TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) (SEE PAGE 31-9)
5. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE)
(SEE PAGE 40-20)
6. REMOVE TRANSFER ASSY (SEE PAGE 31-9)
7. REMOVE CTR DIFFERENTIAL LOCK SLEEVE (SEE PAGE 31-9)
SST 09308-00010
8. REMOVE TRANSFER CASE OIL SEAL
(a) Using SST, remove the oil seal from the case.
SST 09308-00010
NOTICE:
Do not damage the oil-seal-fitted surface of the case.
9. INSTALL TRANSFER CASE OIL SEAL
(a) Using SST, drive a new oil seal into the case to the posi-
tion shown in the illustration.
SST 09387-00010, 09950-70010 (09951-07150)
NOTICE:
Do not install it obliquely.
(b) Apply small amount of MP grease to the oil seal lip.
10. INSTALL CTR DIFFERENTIAL LOCK SLEEVE (SEE PAGE 31-9)
SST 09950-60010 (09951-00610), 09950-70010 (09951-07150)
11. INSTALL TRANSFER ASSY (SEE PAGE 31-9)
12. INSTALL TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) (SEE PAGE 31-9)
13. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (2AZ-FE ENGINE TYPE)
(SEE PAGE 31-9)
14. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE)
(SEE PAGE 40-20)
15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149)
16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24)

100MI-01
A81214
- ENGINE CONTROL SYSTEMACCELERATOR PEDAL ROD ASSY (2AZ-FE)
10-1 1
2369 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
ACCELERATOR PEDAL ROD ASSY (2AZ-FE)
REPLACEMENT
1. REMOVE ACCELERATOR PEDAL ROD ASSY
(a) Disconnect the accelerator pedal position sensor con-
nector.
(b) Remove the 2 bolts and pedal rod.
2. INSTALL ACCELERATOR PEDAL ROD ASSY
(a) Install the pedal rod with the 2 bolts.
Torque: 4.9 NVm (50 kgfVcm, 43 in.Vlbf)
(b) Connect the acceleator pedal position sensor connector.

730KG-01
73-16
- THEFT DETERRENT & DOOR LOCKENGINE IMMOBILIZER SYSTEM
3696 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
ENGINE IMMOBILIZER SYSTEM
REGISTRATION
1. DESCRIPTION OF CODE REGISTRATION
(a) When adding master keys and sub-keys (additional registration).
(1) Register the key code (immobilizer code) in the transponder key ECU.
Target ECUSee step
Transponder key ECU3
(b) When replacing the transponder key ECU (new registration).
(1) Register the key code (immobilizer code) in the transponder key ECU.
Target ECUSee step
Transponder key ECU2
(2) Register the ECU COMMUNICATION ID between the ECM and the transponder key ECU.
Target ECUSee step
ECM5
(c) When replacing the ECM.
(1) Register the ECU COMMUNICATION ID between the ECM and the transponder key ECU.
Target ECUSee step
Transponder key ECU5

Registration begins.
END
START
Insert the key into the ignition key cylinder.
(The registration is completed approx. 1 second after the key is inserted.)
Remove the key.
Register another key?
NoYe s
BLINKING
(Until the first key is
inserted.)
OFF
(Approx. 1 second)
ON
(When the maximum
number of key codes
are registered, the
security indicator re-
mains OFF until the
last key registered is
removed. After it is
removed, the securi-
ty indicator starts
blinking.)
Security Indicator
Automatic Key Code Registration
(New Registration):
- THEFT DETERRENT & DOOR LOCKENGINE IMMOBILIZER SYSTEM
73-17
3697 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
2. KEY REGISTRATION IN AUTOMATIC REGISTRATION (NEW REGISTRATION)
(a) When an ignition key is inserted into the ignition cylinder, the key code (immobilizer code) registration
is automatic. In this mode, a maximum of 4 key codes for 3 master keys and 1 sub-key can be regis-
tered. Any order of registration for the master keys and sub-keys is fine because the transponder key
ECU can distinguish between different types of keys.
HINT:

When a new transponder key ECU is installed, key codes (immobilizer codes) must be registered with
ignition keys.

New transponder key ECUs are automatically set to automatic key code registration mode.

1.8 sec. 0.2 sec.
0.25 sec.
0.5 sec. 0.25 sec.
Code 2-1
Code 2-21 sec. Security Indicator:
Normal
(Immobilizer system is
operating normally.)
ON
OFF
ON
OFF ON
OFF
0.25 sec.1 sec.
0.25 sec.
0.25 sec.1 sec.
0.25 sec.
Code 2-3ON
OFF
0.5 sec.
0.5 sec.
73-18
- THEFT DETERRENT & DOOR LOCKENGINE IMMOBILIZER SYSTEM
3698 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
HINT:

When no key is inserted in the ignition key cylinder in automatic key code registration mode, the securi-
ty indicator remains on.

When the immobilizer system is operating normally and the key is pulled out, the security indicator
blinks continuously.

If the key code registration has failed in automatic key code registration mode, code 2-1 will be output
from the security indicator. Trying to re-register an already registered key will cause code 2-2 to be
output when the key is inserted. If the number of registered key codes exceeds the limit, code 2-3 will
be output from the security indicator. The output details are shown below.
(b) Finish the automatic key code registration mode.
The automatic key code registration mode can be forced to end when at least 1 key code (immobiliser
code) for the master key has been registered.
(1) Turn the ignition switch ON and OFF 5 times within 10 seconds using the already registered mas-
ter key.

- THEFT DETERRENT & DOOR LOCKENGINE IMMOBILIZER SYSTEM
73-19
3699 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
3. REGISTRATION OF ADDITIONAL KEY (ADDITIONAL REGISTRATION)
(a) Register an additional key by using the hand-held tester.
HINT:

A maximum of 5 master key codes and 3 sub-key codes can be registered.

Registration mode will end if each step is not completed within the specified time.

When the ignition cylinder or the key cylinder set is replaced, remove the transmitter module from the
original master key. Then install this transmitter module to a new key and use the new key as the master
key. If necessary, use this master key to register other keys.
NOTICE:
When the ignition key cylinder has been replaced, locking and unlocking doors is possible with the
new master key's transmitter module (taken from the original master key). However, the new master
key will not be able to lock and unlock doors through the door key cylinder. Keep the original master
key. If the new master key's transmitter module's battery fails, the original master key can be used
to lock and unlock doors through the door key cylinder.

Remove the master key.
Insert the already registered master key in the ignition key cylinder and
turn the ignition switch ON.
1. Select HIGHLANDER from the menu.
2. Select IMMOBILISER.
3. Select ID UTILITY.
4. Select TRANSP CODE REG.
After the above operation, proceed to the next step according to the
prompts on the tester screen.
Insert the key to be registered in the ignition key cylinder.
After 60 seconds, the key is registered.
(The security indicator goes off.)
Within 120 seconds
Within 20 seconds
after the tester
instruction
Within 10 seconds
Hand-held tester operation:
END
START Additional Registration
Security Indicator
BLINKING
(Until the first
key is inserted.)
OFF
ON
BLINKING
OFF 73-20
- THEFT DETERRENT & DOOR LOCKENGINE IMMOBILIZER SYSTEM
3700 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)

- THEFT DETERRENT & DOOR LOCKENGINE IMMOBILIZER SYSTEM
73-21
3701 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
HINT:

A brief outline of procedures for key code registration is shown on the previous page. For more detailed
information, please refer to the hand-held tester screen's instructions.

When the immobilizer system is operating normally and the key is pulled out, the security indicator
blinks continuously.

If the key code registration has failed in automatic key code registration mode, code 2-1 will be output
from the security indicator. Trying to re-register an already registered key will cause code 2-2 to be
output when the key is inserted. If the number of registered key codes exceeds the limit, code 2-3 will
be output from the security indicator. The output details are shown in step 2 (new registration).