width TOYOTA HIGHLANDER 2001 Service User Guide

- INTRODUCTIONTERMS
01-43
43 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)Abbreviations Meaning
H-FUSEHigh Current Fuse
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HSGHousing
HTHard Top
HWSHeated Windshield System
ICIntegrated Circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
ISCIdle Speed Control
J/BJunction Block
J/CJunction Connector
KDKick-Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft-Hand
LHDLeft-Hand Drive
L/H/WLength, Height, Width
LLCLong-Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MG1Motor Generator No.1
MG2Motor Generator No.2
MPMultipurpose
MPIMultipoint Electronic Injection
MPXMultiplex Communication System
M/T, MTMManual Transmission (Transaxle)
MTMount
MTGMounting
NNeutral
NANatural Aspiration
No.Number
O2SOxygen Sensor
O/DOverdrive

Timing Marks
A13508
A93962
5
1
3
76
2
4
8
90
Engine FrontPaint
Mark
A50671
A94193
Seal Packing
Seal width: 2.5 to 3.0 mm
A
BC
D
AB
C,D
A,B: 7.5 mm (0.295 in.)
C,D: 4.0 mm (0.1575 in.)
14-54
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2547 Author
: Date
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) Align the timing marks of the No. 1 and No. 2 balance-
shafts as shown in the illustration.
(d) Place the No. 1 and No. 2 balance shafts on the crank
case.
(e) Apply a light coat of engine oil under the heads of the bal-
ance shaft housing bolts.
(f) Uniformly tighten the 8 bolts in the sequence shown in the
illustration.
Torque: 22 NVm (224 kgfVcm, 16 ftVlbf)
HINT:
The balanceshaft housing bolts are tightened in 2 progressive
steps.
(g) Mark the front side of each balance shaft housing bolt
head with paint.
(h) Retighten the bolts by 90 as shown in the illustration.
(i) Check that the painted marks are now at a 90 angle to
the front.
56. INSTALL STIFFENING CRANKCASE ASSY
(a) Apply seal packing in a continuous bead (seal width: 2.5
to 3.0 mm (0.098 to 0.118 in.)) to the places shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the crankcase within 3 minutes after applying
seal packing.

Do not start the engine for at least 2 hours after instal-
ling.

Timing MarksMark Links
Timing Mark
A52513
A53064
SST
A13767
Seal
Packing
Seal Width: 2.0 mm
A90970
Seal PackingSeal Packing
Cylinder
Block Cylinder Head
Gasket
BA
AB
Seal
Packing
Cylinder
Head
14-62
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2555 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(d) Align the mark links (gold or yellow colored links) with the
timing marks of the camshaft timing gear and camshaft
timing sprocket. Then install the chain.
75. INSTALL CHAIN TENSIONER SLIPPER
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
76. INSTALL TIMING CHAIN GUIDE
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
77. INSTALL CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Install the sensor plate with the F mark facing forward.
78. INSTALL TIMING GEAR CASE OR TIMING CHAIN
CASE OIL SEAL
(a) Using SST, tap in a new oil seal until its surface is flush
with the timing chain cover edge.
SST 09223-22010
(b) Apply a light coat of MP grease to the lip of the oil seal.
NOTICE:
Keep the gap between the timing chain cover edge and the
oil seal free of foreign matter.
79. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY
NOTICE:

Remove any oil from the contact surface.

Install the chain cover within 3 minutes after applying
seal packing.

Do not start the engine for at least 2 hours after instal-
ling.
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the timing
chain cover, cylinder head and cylinder block.
(b) Apply seal packing in a continuous bead (seal width: 2.0
mm (0.079 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

A
A
AAA94199
Seal Width:
3.0 to 4.0 mm 2.5 mm
(0.098 in.)
4.0 mm
(0.16 in.)
A77251
Nut
Nut
B
BB
B B BB
B
C
A
C
C
C
C
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-63
2556 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) Apply seal packing in a continuous bead (seal width: 3.0
to 4.0 mm (0.12 to 0.16 in.)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
(d) Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for bolt A
21 NVm (214 kgfVcm, 15 ftVlbf) for bolt B
43NVm (438 kgfVcm, 32 ftVlbf) for bolt C
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for nut
(e) Install the stud bolt to the drive belt tensioner.
Torque: 10 NVm (102 kgfVcm, 7 ftVlbf)

A94202
Seal PackingSeal Width:
3.0 to 4.0 mm6.0 mm
(0.236 in.)
A64641
110 911
12
13
14 8
7
6
5
432
A94203
Seal Width:
2.2 to 2.5 mm
0.5 to 1.0 mm
(0.020 to 0.039 in.)
14-64
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2557 Author
: Date
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
80. INSTALL OIL PAN SUB-ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not start the engine for at least 2 hours after instal-
ling.
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the cylinder
block and oil pan.
(b) Apply seal packing in a continuous bead (seal width: 3.0
to 4.0 mm (0.12 to 0.16 in.)) as shown in the illustration,
and install the oil pan.
Seal packing: Part No. 08826-00080 or equivalent
(c) Uniformly tighten the 12 bolts and 2 nuts in the sequence
shown in the illustration.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
81. INSTALL OIL PAN DRAIN PLUG
(a) Install a new gasket and the drain plug.
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
82. INSTALL WATER PUMP ASSY
(a) Clean the contact surface of the cylinder block.
(b) Apply seal packing in a continuous bead (seal width: 2.2
to 2.5 mm (0.087 to 0.098 in.)) to the outside edge of the
water pump.
Seal packing: Part No. 08826-00100 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the water pump within 5 minutes after applying
seal packing.

Do not start the engine for at least 2 hours after instal-
ling.