drain bolt TOYOTA HIGHLANDER 2001 Service Repair Manual

Explanation of Maintenance Items
37
Differential Oil
Replace at specified intervals. When performing inspections, check each
component for signs of leakage. If you discover any leakage, have it repaired
by a qualified technician immediately.
Drive Belts
Inspect for cracks, excessive wear and oiliness. Check the belt tension and
adjust if necessary. Replace the belts if they are damaged.
Drive Shaft Boots
Check the drive shaft boots and clamps for cracks, deterioration and damage.
Replace any deteriorated or damaged parts and, if necessary, repack the grease.
Selected models also require periodic inspection of the drive shaft bolt for proper
torque. A qualified technician should perform these operations.
Engine Air Filter
Replace at specified intervals. When performing inspections, check for damage,
excessive wear and oiliness, and replace if necessary.
Engine Coolant
Drain and flush the cooling system and refill with an ethyleneglycol type
coolant. Inspect the radiator, condenser and/or intercooler for leaves, dirt and
insects and clean if necessary. Inspect hoses and connections for corrosion and
leaks. Tighten connections and replace parts as necessary. A qualified technician
should perform these operations. (For further details, refer to “Radiator,
Condenser and Hoses” in the “Vehicle Maintenance and Care” section of the
Owner’s Manual.)
Note:YourToyota is equipped with Genuine Toyota Super LongLife Coolant. The
replacementintervals for engine coolant recommended in this booklet are based
on replacement with Genuine Toyota Super LongLife Coolant or similar high
quality nonsilicate, nonamine, nonborate ethyleneglycol coolant with
longlife hybrid organic acid technology (i.e., a combination of low phosphates
and organic acids). If another type of ethyleneglycol coolant is used, replacementintervals may be different.
Engine Oil and Oil Filter
Replace the oil filter and drain and refill the engine oil at specified intervals.
For recommended oil grade and viscosity, refer to the
Owner’s Manual.

31050-02
C82977
No.2 Plug
No.1 Plug
Drain Plug
F45388
- TRANSFERTRANSFER ASSY (4WD)
31-9
3087 Author
: Date
:
TRANSFER ASSY (4WD)
OVERHAUL
HINT:
COMPONENT:
3MZ-FE ENGINE: See page 14-134
2AZ-FE ENGINE: See page 14-15
AUTOMATIC TRANSMISSION (U151E/U151F): See page 40-18
TRANSFER: See page 31-3
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE)
(SEE PAGE 14-149)
2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE)
(SEE PAGE 14-24)
3. REMOVE TRANSFER CASE NO.1 PLUG
(a) Remove the transfer case No.1 plug.
(b) Remove the gasket No.1 from the transfer case No.1
plug.
4. REMOVE TRANSFER CASE NO.2 PLUG
(a) Remove the transfer case No.2 plug.
(b) Remove the gasket No.2 from the transfer case No.2 plug.
5. REMOVE TRANSFER DRAIN PLUG
(a) Remove the transfer drain plug and bleed the transfer oil.
(b) Remove the drain gasket from the transfer drain plug.
6. REMOVE TRANSFER STIFFENER PLATE RH (2AZ-FE
ENGINE TYPE)
(a) Remove the 5 bolts and the stiffener plate RH.
7. REMOVE ENGINE MOUNTING BRACKET RR (2AZ-FE ENGINE TYPE)
(a) Remove the 3 bolts and the engine mounting bracket RR.
8. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE)
(SEE PAGE 40-20)

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)

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.

A942001 5 10 842 6 9 7 3
A53071
A93962
4
8
6
23
7
5
1
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-47
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.

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.

A94202
Seal PackingSeal Width:
3.0 to 4.0 mm6.0 mm
(0.236 in.)
A64641
110 911
12
13
14 8
7
6
5
432
A94203
Seal Width:
2.2 to 2.5 mm
0.5 to 1.0 mm
(0.020 to 0.039 in.)
14-64
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2557 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
80. INSTALL OIL PAN SUB-ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan 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 cylinder
block and oil pan.
(b) Apply seal packing in a continuous bead (seal width: 3.0
to 4.0 mm (0.12 to 0.16 in.)) as shown in the illustration,
and install the oil pan.
Seal packing: Part No. 08826-00080 or equivalent
(c) Uniformly tighten the 12 bolts and 2 nuts in the sequence
shown in the illustration.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
81. INSTALL OIL PAN DRAIN PLUG
(a) Install a new gasket and the drain plug.
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
82. INSTALL WATER PUMP ASSY
(a) Clean the contact surface of the cylinder block.
(b) Apply seal packing in a continuous bead (seal width: 2.2
to 2.5 mm (0.087 to 0.098 in.)) to the outside edge of the
water pump.
Seal packing: Part No. 08826-00100 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the water pump within 5 minutes after applying
seal packing.

Do not start the engine for at least 2 hours after instal-
ling.