TOYOTA HIGHLANDER 2001 Service Repair Manual
Manufacturer: TOYOTA, Model Year: 2001, Model line: HIGHLANDER, Model: TOYOTA HIGHLANDER 2001Pages: 2572, PDF Size: 34.8 MB
Page 2531 of 2572
C50353C83631
SST8.7 to 9.3 mm
(0.343 to 0.366 in.)
C50354
C51160C83692
SST
C50365C83693
C50355C83694
SST
1.1 to 1.9 mm
(0.043 to 0.075 in.)
- TRANSFERTRANSFER ASSY (4WD)
31-31
3109 Author: Date:
70. INSTALL TRANSFER CASE OIL SEAL
(a) Using SST, install the transfer case oil seal to the transfer
case at the position as shown as in the illustration.
SST 09387-00010, 09950-70010 (09951-07150)
NOTICE:
Install the oil seal carefully so that it will not be tilted.
(b) Apply small amount of MP grease to the oil seal lip.
71. INSTALL CTR DIFFERENTIAL LOCK SLEEVE
(a) Coat a new O-ring with hypoid gear oil.
(b) Install the O-ring to the CTR differential lock sleeve.
NOTICE:
Be careful not to twist the O-ring but to fit it properly in the
retainer 's groove.
(c) Using SST, install the CTR differential lock sleeve to the
transfer case.
SST 09950- 60010 (09951- 00610), 09950- 70010
(09951-07150)
(d) Using snap ring pliers, install the shaft snap ring.
NOTICE:
Check that the snap ring is fitted in the groove of the ring
gear mounting case.
72. INSTALL TRANSFER EXTENSION HOUSING TYPE T
OIL SEAL
(a) Using SST, install the transfer extension housing type T
oil seal to the transfer extension housing at the position
as shown in the illustration.
SST 09950- 60010 (09951- 00380, 09951- 00580,
09952-06010), 09950-70010 (09951-07150)
NOTICE:
Install the oil seal carefully so that it will not be tilted.
(b) Apply small amount of MP grease No.2 to the oil seal lip.
Page 2532 of 2572
C50356C83695
SST
C83047C83696
Sealant
C82800
C50332D31105
Sealant-
coated
part
31-32
- TRANSFERTRANSFER ASSY (4WD)
3110 Author: Date:
73. INSTALL TRANSFER EXTENSION HOUSING DUST
DEFLECTOR
(a) Using SST and a press, install a new transfer extension
housing dust deflector to the transfer extension housing
sub-assy .
SST 09950- 60020 (09951- 00710), 09950- 70010
(09951-07150)
74. INSTALL TRANSFER EXTENSION HOUSING
SUB-ASSY
(a) Apply sealant 1281 to the transfer extension housing
sub-assy in continuous beaded form of 1.2 mm diameter
as shown in the illustration.
NOTICE:
Wipe any grease off from the attaching surfaces.
Install the transfer extension housing sub-assy with-
in 10 minutes after applying the sealant.
(b) Install the transfer extension housing sub-assy to the
transfer case with the 4 bolts.
Torque: 26 NVm (260 kgfVcm, 19 ftVlbf)
(c) Remove the transfer assy from the overhaul attachment.
75. INSTALL TRANSFER & TRANSAXLE SETTING STUD
BOLT
(a) Install the 4 transfer & transaxle setting stud bolts to the
parts of the transfer case as shown in the illustration.
Torque: 39 NVm (400 kgfVcm, 30 ftVlbf)
NOTICE:
Install the sealant-coated side of the transfer & transaxle
stud bolt to the transfer case.
Page 2533 of 2572
C69282C83712
6.5 to 7.5 mm
(0.256 to 0.295 in.)
10.8 to 11.8 mm
(0.425 to 0.465 in.)
C51143
C67686
C67689C83713
Sealant
- TRANSFERTRANSFER ASSY (4WD)
31-33
3111 Author: Date:
76. INSTALL TRANSFER CASE STRAIGHT PIN
(a) Using a plastic hammer, install the 4 transfer case straight
pins to the transfer case as shown in the illustration.
77. INSTALL TRANSFER DYNAMIC DAMPER
(a) Install the transfer dynamic damper to the transfer exten-
sion housing sub-assy with the 3 bolts.
Torque: 26 NVm (260 kgfVcm, 19 ftVlbf)
78. INSTALL BREATHER OIL DEFLECTOR
(a) Install the breather oil deflector to the transfer case cover
No.1 with the bolt.
Torque: 6.5 NVm (66 kgfVcm, 57 in.Vlbf)
NOTICE:
Be careful of the direction of the deflector's fold.
79. INSTALL TRANSFER CASE COVER NO.1
(a) Apply sealant 1281 to the transfer case cover No.1 in a
continuous bead of 1.2 mm diameter as shown in the il-
lustration.
NOTICE:
Wipe any grease off from the attaching surfaces.
Install the transfer case cover No.1 within 10 minutes
after application of the sealant.
Page 2534 of 2572
C83507
D30774
SST
C82798
C51159C83714
Driving Plug
Sealant
Gasket
31-34
- TRANSFERTRANSFER ASSY (4WD)
3112 Author: Date:
(b) Install the transfer case cover No.1 to the transfer case
with the 8 bolts.
Torque: 20 NVm (200 kgfVcm, 14 ftVlbf)
80. TRANSFER CASE BREATHER PLUG
(a) Using SST and a hammer, install the transfer case breath-
er plug to the transfer case cover No.1.
SST 09612-10061)
81. INSTALL TRANSFER COVER GASKET
(a) Install a new transfer cover gasket to the transfer case.
82. INSTALL TRANSFER ASSY
(a) Apply sealant 1281 to the transaxle assy and the transfer
assy in continuous beaded form of 1.2 mm diameter as
shown in the illustration.
NOTICE:
Wipe any grease off from the attaching surfaces.
Install it within 10 minutes after applying the sealant.
Sealant stuck on the gasket, case oil seal and driving
plug may cause oil leakage and seizure due to oil
shortage. Care must be taken.
Page 2535 of 2572
C82785
F45388
C82977
No.2 PlugNo.1 Plug
Drain Plug
- TRANSFERTRANSFER ASSY (4WD)
31-35
3113 Author: Date:
(b) Install the transfer assy to the transaxle assy with the 2
bolts and 6 nuts.
Torque: 69 NVm (700 kgfVcm, 51 ftVlbf)
NOTICE:
Check that the gasket is installed to the transfer assy
before instaling them to the transaxle assy.
Install the transfer assy to the transaxle assy without
tilting.
When moving the transfer assy, do not hold the oil
seal on the both sides.
83. INSTALL ENGINE MOUNTING BRACKET RR (2AZ-FE ENGINE TYPE)
(a) Install the engine mounting bracket RR with the 3 bolts.
Torque: 64 NVm (652 kgfVcm, 47 ftVlbf)
84. INSTALL TRANSFER STIFFENER PLATE RH (2AZ-FE
ENGINE TYPE)
(a) Install the stiffener plate RH with the 5 bolts.
Torque: 34 NVm (350 kgfVcm, 25 ftVlbf)
85. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE)
(SEE PAGE 40-20)
86. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149)
87. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24)
88. INSTALL TRANSFER DRAIN PLUG
(a) Install the transfer drain plug with a new drain gasket.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
89. INSTALL TRANSFER CASE NO.2 PLUG
(a) Install the transfer case No.2 plug with a new gasket No.2.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
90. INSTALL TRANSFER CASE NO.1 PLUG
(a) Add oil up to 0 to 5 mm below the lower side of the plug
hole.
Oil quantity: 0.9 L (0.95 US qts, 0.79 lmp. qts)
HINT:
When adding oil, pour it slowly.
(b) Install the transfer case No.1 plug with a new gasket No.1.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
Page 2536 of 2572
141P5-01
SST
A36541
A94204
Timing Marks
Groove
Timing Marks
A53043
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-41
2534 Author: Date:
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.
Page 2537 of 2572
SST
A36684
SST
A36685
A13325
SST
A36335
Bracket
A53037
14-42
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2535 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) Remove the crankshaft pulley.
(1) Using SST, fix the pulley and loosen the bolt.
SST 09213-54015 (91651-60855), 09330-00021
(2) Using SST, remove the bolt and pulley.
SST 09950- 50013 (09951- 05010, 09952- 05010,
09953-05020, 09954-05021)
10. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts, chain tensioner and gasket.
NOTICE:
Do not turn the crankshaft without the chain tensioner.
11. REMOVE WATER PUMP PULLEY
(a) Using SST, remove the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
12. REMOVE WATER PUMP ASSY
(a) Remove the 4 bolts, 2 nuts, bracket and water pump.
Page 2538 of 2572
B12056
A00019
A77251
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-43
2536 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
13. REMOVE OIL PAN DRAIN PLUG
14. REMOVE OIL PAN SUB-ASSY
(a) Remove the 12 bolts and 2 nuts.
(b) Insert the blade of SST between the crankcase and oil
pan. Cut off the applied sealer and remove the oil pan.
SST 09032-00100
NOTICE:
Be careful not to damage the contact surface of the cylin-
der block and oil pan.
15. REMOVE TIMING CHAIN OR BELT COVER
SUB-ASSY
(a) Remove the 14 bolts and 2 nuts.
(b) Remove the timing chain cover by prying between the tim-
ing chain cover and cylinder head or cylinder block with
a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the timing
chain cover, cylinder block and cylinder head.
Page 2539 of 2572
A32626
90
Groove
A52508
Groove
A52509
14-44
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2537 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
16. REMOVE ENGINE REAR OIL SEAL
(a) Using a screwdriver and hammer, remove the oil seal.
17. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
18. REMOVE TIMING CHAIN GUIDE
19. REMOVE CHAIN TENSIONER SLIPPER
20. REMOVE CHAIN VIBRATION DAMPER NO.1
21. REMOVE CHAIN SUB-ASSY
22. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
23. REMOVE NO.2 CHAIN SUB-ASSY
(a) Turn the crankshaft counterclockwise 90, and align the
adjusting hole of the oil pump driven sprocket with the
groove of the oil pump.
(b) Put a bar (f 4 mm (0.16 in.)) in the adjusting hole of the
oil pump driven sprocket to temporarily lock the sprocket
in position. then remove the nut.
Page 2540 of 2572
B11415
A32684
13 5 4 2A36530
12
34 5
A36531
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-45
2538 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) Remove the bolt, chain tensioner plate and spring.
(d) Remove the oil pump sprocket gear,driven sprocket and
chain.
24. REMOVE OIL PUMP ASSY
(a) Remove the 3 bolts, oil pump and gasket.
25. REMOVE NO.2 CAMSHAFT (EXHAUST)
(a) Uniformly loosen and remove the No. 2 camshaft (ex-
haust)'s 10 bearing cap bolts in the sequence shown in
the illustration. Then remove the 5 bearings.
(b) Remove the camshaft.
26. REMOVE CAMSHAFT (INTAKE)
(a) Uniformly loosen and remove the camshaft (intake)'s 10
bearing cap bolts in the sequence shown in the illustra-
tion. Then remove the 5 bearings.
(b) Remove the camshaft.
27. REMOVE CAMSHAFT BEARING NO.1