TOYOTA HIGHLANDER 2001 Service Repair Manual

141P2-01
A94204
Timing Marks
Groove
Timing Marks
A53043
No. 1 Cylinder TDC/Compression
EX
IN
A52469
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VALVE CLEARANCE (2AZ-FE)
ADJUSTMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER SPLASH SHIELD FRONT RH
3. REMOVE FRONT FENDER APRON SEAL RH
4. REMOVE ENGINE COVER SUB-ASSY NO.1
5. REMOVE IGNITION COIL ASSY
6. REMOVE SPARK PLUG
7. DISCONNECT VENTILATION HOSE
8. DISCONNECT VENTILATION HOSE NO.2
9. REMOVE CYLINDER HEAD COVER SUB-ASSY
(a) Remove the bolt and disconnect the engine wire harness
clamp.
(b) Remove the 8 bolts, 2 nuts, cylinder head cover and gas-
ket.
10. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(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 gear
and sprocket are aligned with the timing marks of the
bearing cap No. 1 and No. 2 as shown in the illustration.
11. INSPECT VALVE CLEARANCE
HINT:
Inspect and adjust the valve clearance when the engine is cold.
(a) Check only the valve indicated on the left.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record valve clearance measurements that are out
of the specified range. These measurements will be
used later to determine the size of the adjustment
shim to be installed.

No. 4 Cylinder TDC/Compression
IN
EXA52470
Timing MarkPaint Mark
Timing Mark
Groove Paint Mark
A52471
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Valve clearance (Cold):
ItemSpecified Condition
Intake0.19 to 0.29 mm (0.008 to 0.011 in.)
Exhaust0.30 to 0.40 mm (0.012 to 0.016 in.)
(b) Turn the crankshaft clockwise 1 revolution (360) and set
the No.4 cylinder to TDC/compression.
(c) Check only the valve indicated on the left.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record valve clearance measurements that are out
of the specified range. These measurements will be
used later to determine the size of the adjustment
shim to be installed.
Valve clearance (Cold):
ItemSpecified Condition
Intake0.19 to 0.29 mm (0.008 to 0.011 in.)
Exhaust0.30 to 0.40 mm (0.012 to 0.016 in.)
12. ADJUST VALVE CLEARANCE
NOTICE:
Be sure not to turn the crankshaft without the chain ten-
sioner.
(a) Turn the crankshaft clockwise 1 revolution (360) and set
the No. 1 cylinder to the TDC/compression.
(b) Place paint marks on the timing chain and camshaft tim-
ing gear sprocket.
(c) Remove the 2 bolts and chain tensioner.

FixLoosen
A52454
13 5 4 2A32636
A87614
13 5 4 2
A36526
A52474
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(d) Remove the No. 2 camshaft.
(1) Fix the camshaft with a wrench and then loosen the
sprocket bolt.
NOTICE:
Be careful not to damage the valve lifter.
(2) Uniformly loosen and remove the No. 2 camshaft's
10 bearing cap bolts in the sequence shown in the
illustration. Then remove the 5 bearing caps.
(3) Raise the No. 2 camshaft and remove it. Then re-
move the sprocket bolt.
(4) Remove the camshaft timing sprocket and the tim-
ing chain from the No. 2 camshaft.
(5) Remove the camshaft timing sprocket from the tim-
ing chain.
(e) Remove the camshaft.
(1) Uniformly loosen and remove the camshaft's 10
bearing cap bolts in the sequence shown in the il-
lustration. Then remove the 5 bearing caps.
(2) Remove the camshaft.
(f) Tie the timing chain with a string.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
(g) Remove the valve lifters.

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(h) Adjust the valve clearance.
(1) Using a micrometer, measure the thickness of the
removed lifter.
(2) Calculate the thickness of a new lifter so that the
valve clearance comes within the specified value.
AThickness of new lifter
BThickness of used lifter
CMeasured valve clearance
Valve clearance:
ItemSpecified Condition
IntakeA = B + (C - 0.24 mm (0.0094 in.))
ExhaustA = B + (C - 0.35 mm (0.0138 in.))
EXAMPLE: (Intake)
Measured valve clearance = 0.44 mm (0.0173 in.)
0.44 mm (0.0173 in.) - 0.24 mm (0.0094 in.) = 0.20 mm (0.0079 in.)
(Measured - Specification = Excess clearance)
Used shim measurement = 5.30 mm (0.2087 in.)
0.20 mm (0.0079 in.) + 5.30 mm (0.2087 in.) = 5.50 mm (0.2165 in.)
(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 5.50 mm (0.2165 in.) = Shim No. º50º
(3) Select a new lifter with a thickness as close as pos-
sible to the calculated values.
HINT:

Lifters are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm
(0.2260 in.).

Refer to valve lifter selection chart on the following 2
pages.

A77296
mm (in.)
Lifter
No.
ThicknessLifter
No.ThicknessLifter
No.Thickness
5.540 (0.2181)
5.560 (0.2189)
5.580 (0.2197)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260) 06
08
10
12
14
16
18
20
22
24
26
2830
32
34
36
38
40
42
44
46
48
50
5254
56
58
60
62
64
66
68
70
72
74 5.300 (0.2087)
5.320 (0.2094)
5.340 (0.2102)
5.360 (0.2110)
5.380 (0.2118)
5.400 (0.2126)
5.420 (0.2134)
5.440 (0.2142)
5.460 (0.2150)
5.480 (0.2157)
5.500 (0.2165)
5.520 (0.2173) 5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.220 (0.2055)
5.240 (0.2063)
5.260 (0.2071)
5.280 (0.2079)
Valve Lifter Selection Chart (Intake)
Intake valve clearance (Cold):
0.19 to 0.29 mm (0.008 to 0.011 in.)
EXAMPLE:
The 5.250 mm (0.2067 in.) lifter is installed, and the measured
clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm
(0.2067 in.) lifter with a new No. 42 lifter.
New Lifter Thickness
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A77297
New lifter thickness mm (in.)
Lifter
No.
ThicknessLifter
No.ThicknessLifter
No.Thickness
5.540 (0.2181)
5.560 (0.2189)
5.580 (0.2197)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260) 06
08
10
12
14
16
18
20
22
24
26
2830
32
34
36
38
40
42
44
46
48
50
5254
56
58
60
62
64
66
68
70
72
74 5.300 (0.2087)
5.320 (0.2094)
5.340 (0.2102)
5.360 (0.2110)
5.380 (0.2118)
5.400 (0.2126)
5.420 (0.2134)
5.440 (0.2142)
5.460 (0.2150)
5.480 (0.2157)
5.500 (0.2165)
5.520 (0.2173) 5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.220 (0.2055)
5.240 (0.2063)
5.260 (0.2071)
5.280 (0.2079)
Valve Lifter Selection Chart (Exhaust)
Exhaust valve clearance (Cold):
0.30 to 0.40 mm (0.012 to 0.016 in.)
EXAMPLE:
The 5.340 mm (0.2102 in.) lifter is installed, and the measured
clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm
(0.2102 in.) lifter with a new No. 44 lifter.
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Paint Mark
Timing Marks
A52456
53 1 2 4
Bearing Cap No. 1Bearing Cap No. 3A52457
Timing MarkPaint MarkA53011
A52473
1 3 542
Bearing Cap No. 2 Bearing Cap No. 3
A52458
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(i) Install the camshaft.
(1) Install the timing chain on the camshaft timing gear,
with the paint mark aligned with the timing marks on
the camshaft timing gear.
(2) Examine the front marks and numbers of the 5 bear-
ing caps and install them. Then install the 10 bear-
ing cap bolts. Uniformly tighten the bolts in the se-
quence shown in the illustration.
Torque:
30 NVm (301 kgfVcm, 22 ftVlbf) for bearing cap No. 1
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for bearing cap No. 3
(j) Install the No. 2 camshaft.
(1) Put the No. 2 camshaft on the cylinder head with the
paint mark of the chain aligned with the timing mark
on the camshaft timing sprocket.
(2) Raise the No. 2 camshaft and temporarily tighten
the sprocket bolt.
(3) Examine the front marks and numbers of the 5 bear-
ing caps and install them. Then install the 10 bear-
ing cap bolts. Uniformly tighten the bolts in the se-
quence shown in the illustration.
Torque:
30 NVm (301 kgfVcm, 22 ftVlbf) for bearing cap No. 2
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for bearing cap No. 3

TightenFix
A52459
Paint Mark7 Links
Timing Mark
Groove Paint Mark
Timing Marks
A52460
Raise
PinHook
Push
A52461
Engine
Front
A52462
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(4) Fix the camshaft with a wrench, then tighten the
sprocket bolt.
Torque: 54 NVm (551 kgfVcm, 40 ftVlbf)
NOTICE:
Be careful not to damage the valve lifter.
(k) Check that the timing chain paint marks are aligned with
the camshaft timing sprocket timing mark and the cam-
shaft timing gear timing mark. Also check the alignment
of the pulley groove and chain cover timing mark.
(l) Install the chain tensioner.
(1) Release the ratchet pawl, fully push in the plunger
and apply the hook to the pin so that the plunger
cannot spring out.
(2) Install a new gasket and the chain tensioner with the
2 nuts.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
NOTICE:
When installing the tensioner, set the hook again if the
hook releases the plunger.

A93972
Disconnect
HookPin
Turn
A93973
Plunger
Push
Turn
Seal Packing
A53051
NutNutA61989
A
B A
A
A
A
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(3) Turn the crankshaft counterclockwise, and discon-
nect the plunger knock pin from the hook.
(4) Turn the crankshaft clockwise, and check that the
slipper is pushed by the plunger.
13. INSTALL CYLINDER HEAD COVER SUB-ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to 2 locations as 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 start the engine for at least 2 hours after instal-
ling the cylinder head cover.
(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
14. INSTALL SPARK PLUG
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
15. INSTALL IGNITION COIL ASSY
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
16. INSTALL FRONT WHEEL RH
17. CHECK FOR ENGINE COOLANT LEAKS (See page 16-6)

*The titles given inside the components are the names of the terminals (terminal codes) and are not treated as being
abbreviations.
2005 HIGHLANDER (EWD592U)
17
ABBREVIATIONS D
ABBREVIATIONS
The following abbreviations are used in this manual.
2WD = Two Wheel Drive Vehicles
A/C = Air Conditioning
A/T = Automatic Transaxle
ABS = Anti-Lock Brake System
ACIS = Acoustic Control Induction System
ACM = Active Control Engine Mount
BEAN = Body Electronics Area Network
CAN = Controller Area Network
EC = Electrochromic
ECU = Electronic Control Unit
ESA = Electronic Spark Advance
EVAP = Evaporative Emission
IC = Integrated Circuit
J/B = Junction Block
LH = Left-Hand
O/D = Overdrive
R/B = Relay Block
RH = Right-Hand
SFI = Sequential Multiport Fuel Injection
SRS = Supplemental Restraint System
SW = Switch
TEMP. = Temperature
TRAC = Traction Control
VSC = Vehicle Stability Control
VSV = Vacuum Switching Valve
VVT = Variable Valve Timing
w/ = With
w/o = Without