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 2548 of 2572
EM1628
A36687
A36688
A90850
Matchmarks
Rotating Direction
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-53
2546 Author: Date:
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.
Page 2549 of 2572
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:
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.
Page 2550 of 2572
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
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-55
2548 Author: Date:
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.
Page 2551 of 2572
A36850
Mesh Part
A53039
4545A36835
A90968
Lot No.INTAKE
EXHAUST
Engine
Front
14-56
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2549 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
58. INSTALL W/HEAD TAPER SCREW PLUG NO.1
(a) Apply adhesive to the threads of the plug and install it.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equiva-
lent
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
59. I N S TA L L O I L C O N T R O L VA LV E F I LT E R F O R
CAMSHAFT TIMING
(a) Check that no foreign substance is on the mesh part of the
filter.
(b) Using a 6 mm socket hexagon wrench, install a new gas-
ket and the oil control valve filter with the screw plug.
Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)
60. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSY
(a) Install the water drain cock within the range shown in the
illustration.
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
61. INSTALL CYLINDER HEAD GASKET
(a) Place a new gasket on the cylinder block surface with the
Lot No. stamp upward.
NOTICE:
Remove any oil from contact surface.
Be careful of the installation direction.
To avoid damage to the gasket, place the cylinder
head on the gasket carefully.
62. INSTALL CYLINDER HEAD SUB-ASSY
HINT:
The cylinder head bolts are tightened in 2 progressive steps.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install the 10 bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.
Page 2552 of 2572
A941951 6 10 3 79 5 2 4 8
A00976
90
Engine
Front
Paint Mark
A53074
A13383
Straight
Pin
Key
Groove
A31033
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-57
2550 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) Using a 10 mm bi-hexagon wrench, uniformly tighten the
10 bolts in the sequence shown in the illustration.
Torque: 79 NVm (806 kgfVcm, 58 ftVlbf)
(d) Mark the front side of each cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90 in the sequence
shown in the illustration.
(f) Check that the painted marks are now at a 90 angle to
the front.
63. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
64. INSTALL CAMSHAFT BEARING NO.2
(a) Install the bearing to the camshaft.
NOTICE:
Clean the contact surfaces of the bearing and the cylinder
head. the surfaces should be free of dust and oils.
65. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear and the camshaft together
with the straight pin and key groove.
(b) Turn the camshaft timing gear (as shown in the illustra-
tion) while pushing it lightly against the camshaft. Push
further at the position where the pin enters the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retarded
angle side (to the right angle).
(c) Check that there is no clearance between the gear's
fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 NVm (551 kgfVcm, 40 ftVlbf)
Page 2553 of 2572
A32167
A92649
12 34 5
Bearing Cap No. 1Bearing Cap No. 3
A94196
Bearing Cap No. 2
Bearing Cap No. 3
53 1 2 4 14-58
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2551 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(e) Check that the camshaft timing gear can move to the re-
tarded angle side (the right direction) and is locked at the
extreme retarded angle position.
HINT:
Apply a light coat of engine oil on the threads and under
the heads of the bolt.
Length of sprocket bolt excluding bolt head: 40 mm (1.57
in.)
66. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
(a) Fix the camshaft with a vise, and install the camshaft No.
2 timing gear.
Torque: 54 NVm (551 kgfVcm, 40 ftVlbf)
HINT:
Apply a light coat of engine oil on the threads and under
the heads of the bolt.
Length of sprocket bolt excluding bolt head: 25 mm (0.98
in.)
67. INSTALL CAMSHAFT BEARING NO.1
68. INSTALL CAMSHAFT (INTAKE)
(a) Examine the front marks and numbers of the 5 bearing
caps and install them. Then install the 10 bearing cap
bolts. Uniformly tighten the bolts in the sequence shown
in the illustration.
Torque:
30 NVm (306 kgfVcm, 22 ftVlbf) for bearing cap No. 1
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for bearing cap No. 3
NOTICE:
Tighten the bolts after deciding the position for the
thrust direction of the camshaft by the bearing cap
No. 1.
Install the camshaft with its timing mark of the cam-
shaft timing gear on top.
69. INSTALL NO.2 CAMSHAFT (EXHAUST)
(a) Examine the front marks and numbers of the 5 bearing
caps and install them. Then install the 10 bearing cap
bolts. Uniformly tighten the bolts in the sequence shown
in the illustration.
Torque:
30 NVm (306 kgfVcm, 22 ftVlbf) for bearing cap No. 2
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for bearing cap No. 3
Page 2554 of 2572
A32684
B11424
A94198
Timing Mark
Mark Link Timing MarkMark Link
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-59
2552 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
NOTICE:
Tighten the bolts after deciding the position for the
thrust direction of the camshaft by the bearing cap
No. 2.
Install the camshaft with its timing mark of the cam-
shaft timing gear on top.
70. INSTALL OIL PUMP ASSY
(a) Install a new gasket and oil pump with the 3 bolts.
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
71. INSTALL NO.2 CHAIN SUB-ASSY
(a) Set the crankshaft key into the left horizontal position.
(b) Turn the cutout of the drive shaft to the top.
(c) Align the mark links (yellow colored links) with the timing
marks of the sprocket as shown in the illustration.
(d) Insert the sprocket with chain to the crankshaft and oil
pump shaft.
(e) Temporarily tighten the oil pump driven sprocket with the
nut.
Page 2555 of 2572
A90851
Chain Tensioner Plate
Bolt
Spring
Groove
A52512
90
A36525
14-60
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2553 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(f) Insert the damper spring into the adjusting hole, and
install the chain tensioner plate by the bolt.
Torque: 12 NVm (122 kgfVcm, 9.0 ftVlbf)
(g) Align the adjusting hole of the sprocket with the groove of
the oil pump.
(h) Put a bar (f 4 mm (0.16 in.)) into the adjusting hole of the
sprocket to temporarily lock the sprocket in position.
Install the nut.
Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)
(i) Rotate the crankshaft clockwise 90, and align the crank-
shaft key with the top.
72. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
73. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
Page 2556 of 2572
Timing Marks
Timing Marks
A53018
A52505
Mark Link
Timing Mark
A52523
SST
A13337
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-61
2554 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
74. INSTALL CHAIN SUB-ASSY
(a) Set the No. 1 cylinder to TDC/compression.
(1) Align the timing marks of the camshaft timing gear/
sprocket and bearing caps (No. 1 and No. 2).
(2) Using the crankshaft pulley bolt, turn the crankshaft
and set the set key on the crankshaft upward.
(b) Align the mark link (blue or orange colored link) with the
timing mark of the crankshaft timing sprocket.
(c) Using SST, tap in the sprocket.
SST 09309-37010
Page 2557 of 2572
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: Date:
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