2001 TOYOTA HIGHLANDER length

R00429
Marked Line
F16018
- STEERING COLUMNSTEERING SYSTEM
50-5
3266 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(7) Convert the measured distance to steering angle.
Measured distance 1 mm (0.04 in.) = Steering angle of
approximately 1 degree.
HINT:
Make a note of the steering angle.
(b) Adjust steering angle.
(1) Draw a line on the RH and LH tie rod ends and rack
ends respectively where it can be easily seen.
(2) Using a paper gauge, measure the distance from
the RH and LH tie rod ends to the rack end screws.
HINT:

Measure both the RH and LH sides.

Make a note of the measured values.
(3) Remove the RH and LH boot clips from the rack
boots.
(4) Loosen the RH and LH lock nuts.
(5) Turn the RH and LH rack ends by the same amount
(but in different directions) according to the steering
angle.
One 360 degree turn of rack end (1.5 mm (0.059 in.)
horizontal movement) eguals to 12 degrees of steer-
ing angle.
(6) Tighten the RH and LH lock nuts by the specified
torque.
Torque: 74 N´m (750 kgf´cm, 54 ftVlbf)
NOTICE:
Make sure that the difference in length between the RH and
LH tie rod ends and rack end screws are within 1.5 mm
(0.059 in.).
(7) Install the RH and LH boot clips.

031WC-01
03-36
- SERVICE SPECIFICATIONSREAR SUSPENSION
157 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
REAR SUSPENSION
SERVICE DATA
Rear wheel align-
Toe-in (total)
No.2 lower suspension arm length difference: FF
4WD
0
18'
12' (0.3

0.2
, 3
2 mm, 0.12
0.08 in.)
1.5 mm (0.06 in.) or less
1.0 mm (0.04 in.) or less
Rear wheel align
mentCamber
FF
4WD
Right-left error
-1°20' ± 45' (-1.33° ± 0.75°)
-0°45' ± 45' (-0.75° ± 0.75°)
45' (0.75°) or less
Rear SuspensionStabilizer link ball joint turning torque1.0 NVm (10 kgfVcm, 9 in.Vlbf) or less

C82790
C82791
C82792C83635
SST
C50309
31-12
- TRANSFERTRANSFER ASSY (4WD)
3090 Author
: Date
:
20. REMOVE TRANSFER EXTENSION HOUSING
SUB-ASSY
(a) Remove the 4 bolts.
(b) Using a plastic hammer, remove the transfer extension
housing sub-assy from the transfer case.
21. INSPECT PRELOAD
(a) Using SST and a torque wrench, check the initial torque
within the backlash range.
SST 09326-2001 1
Torque (preload): 0.9 to 1.4 NVm
(9 to 14 kgfVcm, 8.0 to 12.4 in.Vlbf)
HINT:

Use a torque wrench with a fulcrum length of 160 mm
(6.30 in.)

If the value is out of standard range, replace the driven
pinion bearing.
(b) Using SST and a torque wrench, check the initial torque
while the driven pinion is in contact with the ring gear face.
SST 09326-2001 1
Torque: Preload + 0.15 to 0.30 NVm
(+1.6 to 3.1 kgfVcm, +1.3 to 2.7 in.Vlbf)
HINT:

Use a torque wrench with a fulcrum length of 160 mm
(6.30 in.)

If the value is out of standard range, overhaul the transfer.
22. INSPECT BACKLASH
(a) Set the dial indicator perpendicular to the tooth face of the
ring gear, fix the driven pinion and inspect the backlash
while moving the gear.
Backlash: 0.10 to 0.15 mm (0.0039 to 0.0059 in.)
NOTICE:
Inspect it at 3 points or more on the gear's periphery.
HINT:
Write down the result.

C82983
SST
C82792C83635
SST
SA1143
Boiling Water
- TRANSFERTRANSFER ASSY (4WD)
31-21
3099 Author
: Date
:
(c) Using SST, tighten a new transfer gear nut (at a standard
torque.)
SST 09326-2001 1, 09556-16030
Torque:
277 to 378 NVm (2,820 to 3,855 kgfVcm, 204 to 279 ftVlbf)
NOTICE:
Do not stake the transfer gear nut.
HINT:
Use a torque wrench with a fulcrum length of 750 mm (29.53 in.)
50. INSPECT AND ADJUST DRIVEN PINION PRELOAD
(a) Using SST and a torque wrench, measure the initial
torque of the driven pinion.
Preload (at starting):
New bearing:
1.1 to 1.6 NVm (11 to 16 kgfVcm, 9.7 to 14.2 in.Vlbf)
Used bearing:
0.9 to 1.4 NVm (9 to 14 kgfVcm, 8.0 to 12.4 in.Vlbf)
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.30 in.)
NOTICE:
Measure preload after rotating the bearing both clockwise
and counterclockwise to make it fit.
(b) If the preload is too large, replace the transfer pinion
bearing spacer with a new one.
(c) If the preload is too small, repeatedly adjust the preload
by tightening the transfer gear nut 5 to 10 degrees at a
time until the standard value is obtained.
(d) If the preload is insufficient, even though the tightening
torque of the transfer gear nut exceeds the maximum of
the standard value, loosen the transfer gear nut and apply
gear oil SAE 90 (GL-5) to the transfer gear nut and the
screw thread and the base of the driven pinion. And then
repeat the preceding operation. If the tightening torque is
smaller than the standard, replace the transfer pinion
bearing spacer with a new one and adjust it.
SST 09326-2001 1, 09556-16030
Torque: 378 NVm (3,855 kgfVcm, 279 ftVlbf)
51. INSTALL RING GEAR
(a) Completely remove grease and moisture on the contact
surfaces of the ring gear and the transfer ring gear mount-
ing case.
(b) Heat the ring gear in boiling water from 90 to 100C (194
to 212F).
(c) Carefully take the ring gear out of the boiling water.

C50363C83656
Transfer Output Washer
C82792C83635
SST 31-26
- TRANSFERTRANSFER ASSY (4WD)
3104 Author
: Date
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(d) The location of the transfer output washer for tooth con-
tact adjustment is shown in the illustration.
59. ADJUST TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the initial
torque with the driven pinion being contact with the ring
gear face.
SST 09326-2001 1
Torque:
New bearing:
Driven pinion preload +0.2 to 0.4 NVm
(+2.3 to 3.9 kgfVcm, 1.8 to 3.5 in.Vlbf)
Used bearing:
Driven pinion preload +0.15 to 0.30 NVm
(+1.6 to 3.1 kgfVcm, 1.3 to 2.7 in.Vlbf)
NOTICE:
Before measurement, rotate the bearing in both directions
several times to make it fit.
HINT:
Use a torque wrench with a fulcrum length of 160 mm (6.30 in.).
(b) If the value is out of standard range, select the washer for
the center differential case tapered roller bearing RH side
from the following table and replace it.
MarkWasher Thickness mm (in.)MarkWasher Thickness mm (in.)MarkWasher Thickness mm (in.)
AA1.47 (0.0578)AB1.50 (0.0590)AC1.53 (0.0602)
BA1.56 (0.0614)BB1.59 (0.0625)BC1.62 (0.0637)
CA1.65 (0.0649)CB1.68 (0.0661)CC1.71 (0.0673)
DA1.74 (0.0685)DB1.77 (0.0696)DC1.80 (0.0708)
EA1.83 (0.0720)EB1.86 (0.0732)EC1.89 (0.0744)
FA1.92 (0.0755)FB1.95 (0.0767)FC1.98 (0.0779)
GA2.01 (0.0790)GB2.04 (0.0803)GC2.07 (0.0814)
HA2.10 (0.0826)HB2.13 (0.0838)HC2.16 (0.0850)
JA2.19 (0.0862)JB2.22 (0.0874)JC2.25 (0.0885)
KA2.28 (0.0897)KB2.31 (0.0909)KC2.34 (0.0921)
LA2.37 (0.0933)LB2.40 (0.0944)LC2.43 (0.0956)
MA2.46 (0.0968)MB2.49 (0.0980)MC2.52 (0.0992)
NA2.55 (0.1003)NB2.58 (0.1015)

C57489
C83509
C82792C83650
SST
C50351C83691SST
0.7 to 1.3 mm
(0.028 to 0.051 in.)
31-30
- TRANSFERTRANSFER ASSY (4WD)
3108 Author
: Date
:
(e) After inserting the transfer RH bearing retainer sub-assy
into the transfer case, remove the SST.
(f) Tighten the 7 bolts.
Torque: 28 NVm (286 kgfVcm, 21 ftVlbf)
68. INSPECT TOTAL PRELOAD
(a) Using SST and a torque wrench, measure the initial
torque with the driven pinion being in contact with the ring
gear face.
SST 09326-2001 1
Torque:
New bearing:
Driven pinion preload +0.2 to 0.4 NVm
(+2.3 to 3.9 kgfVcm, 1.8 to 3.5 in.Vlbf)
Used bearing:
Driven pinion preload +0.15 to 0.30 NVm
(+1.6 to 3.1 kgfVcm, +1.3 to 2.7 in.Vlbf)
HINT:

Use a torque wrench with a fulcrum length of 160 mm
(6.30 in.).

If the preload is too large, inspect the transfer RH bearing
retainer sub-assy.
69. INSTALL TRANSFER RH BEARING RETAINER OIL
SEAL
(a) Using SST, install the transfer RH bearing retainer oil seal
to the transfer RH bearing retainer sub-assy to the posi-
tion as shown in the illustration.
SST 09223-4601 1
NOTICE:
Install the oil seal carefully so that it will not be tilted.
(b) Apply MP grease to the oil seal lip.

A36686
A94201
Specified Bolt Length
MoveRaise
Lock
A53049
A57478
15 Links 115.4 mm
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-51
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.

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