engine TOYOTA HIGHLANDER 2001 Service Repair Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2001, Model line: HIGHLANDER, Model: TOYOTA HIGHLANDER 2001Pages: 2572, PDF Size: 34.8 MB
Page 2538 of 2572
B12056
A00019
A77251
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
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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.
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A32626
90
Groove
A52508
Groove
A52509
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- 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.
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B11415
A32684
13 5 4 2A36530
12
34 5
A36531
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
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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
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A32167
A90848
Advanced
Angle Side
A31032
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- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2539 Author: Date:
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.
Page 2542 of 2572
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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2540 Author: Date:
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.
Page 2543 of 2572
A90849
Plastigage
A93962
5
1
3
76
2
4
8
90
Engine FrontPaint
Mark
A50671
A13392
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2541 Author: Date:
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.
Page 2544 of 2572
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
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
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2542 Author: Date:
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.
Page 2545 of 2572
A53035
A53036
A53035
A33838
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- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2543 Author: Date:
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.
Page 2546 of 2572
A36686
A94201
Specified Bolt Length
MoveRaise
Lock
A53049
A57478
15 Links 115.4 mm
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
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2544 Author: Date:
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.
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A30206
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A36688
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2545 Author: Date:
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.