air filter TOYOTA HIGHLANDER 2001 Service Manual PDF

'05 HIGHLANDER_U (L/O 0409)
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
Where to obtain the
Repair Manual
The repair manual for HIGHLANDER may be pur-
chased from any Toyota dealer or the Material Dis-
tribution Center. To purchase the repair manual,
please contact your Toyota dealer or call the Mate-
rial Distribution Center toll- free at
1- 800- 622- 2033.
Maintenance procedures for the engine,
chassis, body, electrical system, and more,
are clearly explained and illustrated.
Periodic maintenance and tune-up
Periodic maintenance and tune- up helps to prevent
small problems from growing into larger ones later on.
The repair manual outlines exactly what maintenance
is required and clearly explains how to do the work
yourself step- by- step.
Areas covered include such things as spark plug re-
placement, valve clearance adjustment and engine oil
and filter replacement.

120E5-01
A88556
Carbon Filter
Charcoal Canister Filter
VSV for CCV ECM
Charcoal Canister Refueling Valve
Restrictor Passage Vapor Pressure Sensor
Fuel Tank
Purge Line
Fresh Air Line EVAP
Service Port Purge ValveAir Cleaner 12-16
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
SYSTEM DIAGRAM
The emission control system is determined by the ECM based on signals from various sensors.

141P5-01
SST
A36541
A94204
Timing Marks
Groove
Timing Marks
A53043
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
OVERHAUL
1. REMOVE OIL FILTER SUB-ASSY
(a) Using SST, remove the oil filter.
SST 09228-06501
2. REMOVE OIL FILTER UNION
(a) Using a 12 mm hexagon wrench, remove the union.
3. REMOVE OIL FILLER CAP SUB-ASSY
4. REMOVE VENTILATION VALVE SUB-ASSY
5. REMOVE SPARK PLUG
6. REMOVE CYLINDER HEAD COVER SUB-ASSY
(a) Remove the 8 bolts, 2 nuts, and cylinder head cover.
7. REMOVE CYLINDER HEAD COVER GASKET
8. REMOVE CRANKSHAFT POSITION SENSOR
9. REMOVE CRANKSHAFT PULLEY
(a) Turn the crankshaft pulley and align its groove with timing
mark 0 of the timing chain cover.
(b) Check that the timing marks of the camshaft timing
sprockets are aligned with the timing marks of the No. 1
bearing cap, as shown in the illustration.

A942001 5 10 842 6 9 7 3
A53071
A93962
4
8
6
23
7
5
1
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
30. REMOVE CAMSHAFT BEARING NO.2
31. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
32. REMOVE CYLINDER HEAD SUB-ASSY
(a) Using a 10 mm bi-hexagon wrench, uniformly loosen the
10 bolts in the sequence shown in the illustration. Re-
move the 10 cylinder head bolts and plate washers.
NOTICE:

Be careful not to drop the washers into the cylinder
head.

Head warpage or cracking could result from remov-
ing bolts in an incorrect order.
33. REMOVE CYLINDER HEAD GASKET
34. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
35. REMOVE OIL CONTROL VALVE FILTER
(a) Using a 6 mm socket hexagon wrench, remove the plug and filter.
36. REMOVE W/HEAD TAPER SCREW PLUG NO.1
37. INSPECT BALANCESHAFT THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance while
moving the balanceshaft back and forth.
Standard thrust clearance:
0.050 to 0.090 mm (0.0020 to 0.0035 in.)
Maximum thrust clearance: 0.090 mm (0.0035 in.)
If the thrust clearance is greater than the maximum, replace the
balanceshaft housing and bearings. If necessary, replace the
balance shaft.
38. INSPECT BALANCESHAFT OIL CLEARANCE
(a) Uniformly loosen and remove the 8 bolts in the sequence
shown in the illustration.
NOTICE:
Be careful not to damage the contact surfaces of the balan-
ceshaft housing and crankcase.
HINT:
Keep the lower bearing and balanceshaft housing together.
(b) Lift out the No. 1 and No. 2 balanceshafts.
HINT:
Keep the upper bearing with the crankcase.
(c) Clean each bearing and journal.
(d) Check each bearing and journal for pitting and scratches.
If a bearing or journal is damaged, replace the bearings. If nec-
essary, replace the balance shaft.
(e) Place the No. 1 and No. 2 balanceshafts on the crank-
case.

A36850
Mesh Part
A53039
4545A36835
A90968
Lot No.INTAKE
EXHAUST
Engine
Front
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- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
58. INSTALL W/HEAD TAPER SCREW PLUG NO.1
(a) Apply adhesive to the threads of the plug and install it.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equiva-
lent
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
59. I N S TA L L O I L C O N T R O L VA LV E F I LT E R F O R
CAMSHAFT TIMING
(a) Check that no foreign substance is on the mesh part of the
filter.
(b) Using a 6 mm socket hexagon wrench, install a new gas-
ket and the oil control valve filter with the screw plug.
Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)
60. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSY
(a) Install the water drain cock within the range shown in the
illustration.
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
61. INSTALL CYLINDER HEAD GASKET
(a) Place a new gasket on the cylinder block surface with the
Lot No. stamp upward.
NOTICE:

Remove any oil from contact surface.

Be careful of the installation direction.

To avoid damage to the gasket, place the cylinder
head on the gasket carefully.
62. INSTALL CYLINDER HEAD SUB-ASSY
HINT:
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 10 bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.

A94205
Seal Packing
Seal Packing
A94204NutNut AA A A
B
AABB
SST
A36541
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
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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