TOYOTA HIGHLANDER 2001 Service Repair Manual

A32167
A90848
Advanced
Angle Side
A31032
A32639
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
28. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET
(a) Fix the camshaft with a vise and remove the camshaft tim-
ing sprocket.
NOTICE:
Be careful not to damage the camshaft.
29. REMOVE CAMSHAFT TIMING GEAR ASSY
(a) Fix the camshaft with a vise, and make sure that the cam-
shaft timing gear does not move.
(b) Cover all the oil ports with vinyl tape except the advanced
angle side, as shown in the illustration.
(c) Using an air gun, apply about 150 kPa (1.5 kgf/cm
2, 21
psi) of air pressure to the port on the advanced angle side.
CAUTION:
Some oil spraying will occur. Contain the spray with a shop
rag.
HINT:
This operation releases the lock pin for the extreme retarded
angle lock.
(d) Under the condition above, check that the camshaft tim-
ing gear can be turned by hand to the advanced angle
side (counterclockwise), the direction of the arrow shown
in the illustration.
Standard: Must turn
HINT:
The camshaft timing gear will turn to the advanced angle side
without applying force by hand depending on the force of the
air pressure applied. Also, if applying pressure to the oil path is
difficult as a result of air leakage from the port, the lock-pin may
be difficult to release.
(e) Remove the fringe bolt from the camshaft timing gear.
NOTICE:

Be sure not to remove the other 4 bolts.

If planning to reuse the camshaft timing gear, release
the straight pin lock first, and then install the gear.

A942001 5 10 842 6 9 7 3
A53071
A93962
4
8
6
23
7
5
1
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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.

A90849
Plastigage
A93962
5
1
3
76
2
4
8
90
Engine FrontPaint
Mark
A50671
A13392
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(f) Lay a strip of Plastigage across each journal, and install
the balanceshaft housing.
(g) Apply a light coat of engine oil on the threads and under
the heads of the balanceshaft housing bolts.
(h) Uniformly tighten the 8 bolts in the sequence shown in the
illustration.
Torque: 22 NVm (220 kgfVcm, 16 ftVlbf)
HINT:
The balanceshaft housing bolts are tightened in 2 progressive
steps.
(i) Mark the front side of each balanceshaft housing bolt
head with paint.
(j) Retighten the bolts 90 as shown in the illustration.
(k) Check that the paint marks are now at a 90 angle to the
front.
(l) Remove the balanceshaft housing, and measure the
Plastigage at its widest point.
Standard oil clearance:
0.004 to 0.031 mm (0.0002 to 0.0012 in.)
Maximum oil clearance: 0.031 mm (0.0012 in.)
(m) Completely remove the Plastigage after the inspection.

No. 1
Shaft FR
Mark No. 2
Shaft FRNo. 2
Shaft RRNo. 1
Shaft RR
A53040
Cut Position
A13493
A94192
1
105984
26
73
11
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
If the clearance is greater than the maximum, replace the bear-
ing. If necessary, replace the balanceshaft.
If using a standard bearing, replace it with one of the same num-
ber.
Balanceshaft housing journal bore diameter:
Mark 126.000 to 26.006 mm (1.0236 to 1.0239 in.)
Mark 226.007 to 26.012 mm (1.0239 to 1.0241 in.)
Mark 326.013 to 26.018 mm (1.0241 to 1.0243 in.)
Balanceshaft journal diameter:
22.985 to 23.000 mm (0.9049 to 0.9055 in.)
Standard bearing center wall thickness:
Mark 11.486 to 1.489 mm (0.0585 to 0.0586 in.)
Mark 21.489 to 1.492 mm (0.0586 to 0.0587 in.)
Mark 31.492 to 1.495 mm (0.0587 to 0.0589 in.)
(n) Completely remove the Plastigage after the inspection.
39. REMOVE BALANCESHAFT
40. REMOVE BALANCESHAFT BEARING NO. 1
41. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver with its tip taped, pry out the oil seal.
NOTICE:
After the removal, check the crankshaft for damage. If it is
damaged, smooth the surface with 400-grit sandpaper.
42. REMOVE STIFFENING CRANKCASE ASSY
(a) Uniformly loosen and remove the 11 bolts in the se-
quence shown in the illustration.
(b) Using a screwdriver, remove the crankcase by prying the
portions between the crankcase and cylinder block.
NOTICE:
Be careful not to damage the contact surfaces of the crank-
case and cylinder block.
(c) Remove the O-ring from the cylinder block.

A53035
A53036
A53035
A33838
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
43. INSPECT OIL PUMP DRIVE SPROCKET
(a) Wrap the chain around the drive gear.
(b) Using a vernier caliper, measure the sprocket diameter
with the chain.
Minimum sprocket diameter (w/chain):
48.2 mm (1.898 in.)
NOTICE:
The vernier caliper must contact the chain rollers for the
measurement.
If the diameter is less than the minimum, replace the chain and
sprocket.
44. INSPECT OIL PUMP DRIVEN SPROCKET
(a) Wrap the chain around the drive shaft gear.
(b) Using a vernier caliper, measure the sprocket diameter
with the chain.
Minimum gear diameter (w/chain): 48.2 mm (1.898 in.)
NOTICE:
The vernier caliper must contact the chain rollers for the
measurement.
If the diameter is less than the minimum, replace the chain and
sprocket.
45. INSPECT CRANKSHAFT TIMING GEAR OR
SPROCKET
(a) Wrap the chain around the timing gear.
(b) Using a vernier caliper, measure the timing gear diameter
with the chain.
Minimum gear diameter (w/ chain): 51.6 mm (2.031 in.)
NOTICE:
The vernier caliper must contact the chain rollers for the
measurement.
If the diameter is less than the minimum, replace the chain and
timing gear.
46. INSPECT CHAIN TENSIONER SLIPPER
(a) Measure the tensioner slipper wear.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the tensioner
slipper.

A36686
A94201
Specified Bolt Length
MoveRaise
Lock
A53049
A57478
15 Links 115.4 mm
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
47. INSPECT CHAIN VIBRATION DAMPER NO.1
(a) Measure the vibration damper wear.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than the maximum, replace the vibration
damper.
48. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier caliper, measure the length of the head
bolts from the seat to the end.
Standard bolt length:
161.3 to 162.7 mm (6.3503 to 6.4055 in.)
Maximum bolt length: 164.2 mm (6.4646 in.)
If the length is greater than the maximum, replace the bolt.
49. INSPECT CHAIN TENSIONER ASSY NO.1
(a) Check that the plunger moves smoothly when the ratchet
pawl is raised.
(b) Release the ratchet pawl and check that the plunger is
locked in place by the ratchet pawl and does not move
when pushed with your finger.
50. INSPECT CHAIN SUB-ASSY
(a) Using a vernier caliper, measure the length of 15 links with
the chain fully stretched.
Maximum chain elongation: 115.4 mm (4.543 in.)
NOTICE:
Make the same measurements pulling at 3 or more places
selected at random. Average the measurements.
If the elongation is greater than the maximum, replace the
chain.

A30206
EM1628
A36687
A36688
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
51. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
(a) Wrap the chain around the timing sprocket.
(b) Using a vernier caliper, measure the timing sprocket di-
ameter with the chain.
Minimum sprocket diameter (w/chain):
97.3 mm (3.831 in.)
NOTICE:
The vernier caliper must contact the chain rollers for the
measurement.
If the diameter is less than the minimum, replace the chain and
timing gear.
52. INSPECT CAMSHAFT (INTAKE)
(a) Check the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.03 mm (0.0012 in.)
If the circle runout is greater than the maximum, replace the
camshaft.
(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
46.495 to 46.595 mm (1.8305 to 1.8344 in.)
Minimum cam lobe height: 46.385 mm (1.8262 in.)
If the cam lobe height is less than the minimum, replace the
camshaft.
(c) Using a micrometer, measure the journal diameter.
No. 1 journal diameter:
35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journal diameter:
22.959 to 22.975 mm (0.9039 to 0.9045 in.)
If the journal diameter is not as specified, check the oil clear-
ance.

EM1628
A36687
A36688
A90850
Matchmarks
Rotating Direction
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
53. INSPECT NO.2 CAMSHAFT (EXHAUST)
(a) Check the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.03 mm (0.0012 in.)
If the circle runout is greater than the maximum, replace the
camshaft.
(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
45.983 to 46.083 mm (1.8104 to 1.8143 in.)
Minimum cam lobe height: 45.873 mm (1.8060 in.)
If the cam lobe height is less than the minimum, replace the
camshaft.
(c) Using a micrometer, measure the journal diameter.
No. 1 journal diameter:
35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journal diameter:
22.959 to 22.975 mm (0.9039 to 0.9045 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
54. INSTALL BALANCESHAFT BEARING NO.1
(a) Install the bearings in the crankcase and balanceshaft housing.
(b) Apply a light coat of engine oil on the bearings.
55. INSTALL BALANCESHAFT NO. 1 AND NO. 2
(a) Rotate the driven gear No. 1 of balanceshaft No. 1 for the
rotating direction until it hits the stopper.
(b) Confirm that the matchmarks on driven gear No. 1 and
No. 2 are matched.

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.)
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(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.

O-ring
A53026
A91021
No. 1
Crank Pin
Timing Marks
A94192
1 3 7 11 48
9 5 2 6 10
A94194
Timing Marks
Key
SSTA32658
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(b) Place a new O-ring on the cylinder block, as shown in the
illustration.
(c) With the No. 1 crank pin of the crankshaft placed at 6
o'clock, install the No. 1 and No. 2 balanceshaft and the
adjusting hole as shown in the illustration.
(d) Uniformly tighten the 11 bolts in the sequence shown in
the illustration.
Torque: 33 NVm (337 kgfVcm, 24 ftVlbf)
(e) Confirm that the timing marks of the balanceshafts are
matched when the key groove is placed at 6 o'clock, as
shown in the illustration.
57. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
NOTICE:
Keep the lip off the foreign materials.
(b) Using SST and a hammer, evenly tap the oil seal until its
surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)
NOTICE:
Wipe off extra grease on the crankshaft.