Page 2545 of 2572

A53035
A53036
A53035
A33838
14-50
- 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)
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.
Page 2547 of 2572

A30206
EM1628
A36687
A36688
14-52
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
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.
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)