Page 729 of 2572

'05 HIGHLANDER_U (L/O 0409)
287
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
2. Slide the cross rails to the appropri-
ate position for loading the luggages
and turn the side knobs clockwise to
tighten the cross rails securely.
Vehicles with the electric moon
roofÐThere are cross rail stoppers on the
roof rails which help you prevent the
cross rails being touched with the tilted up
moon roof.
NOTICE
Vehicles with the electric moon roof
onlyÐDo not remove the cross rail
stoppers, or the moon roof may be
damaged when it is tilted.
3. In order to fix the cross rails to the
appropriate length, turn the upper
knobs clockwise after tightening all
of the side knobs.
CAUTION
Make sure the cross rails are fixed
securely by pushing forward and rear-
ward them. Failure to do so may
cause an unexpected accident or se-
vere injury in the event of emergency
braking or a collision.
Follow the manufacture's instructions and
precautions when installing the attach-
ments or their equivalent.
CAUTION
When you load cargo on the roof lug-
gage carrier, observe the following:
Place the cargo so that its weight
is distributed evenly between the
front and rear axles.
If loading long or wide cargo, never
exceed the vehicle overall length or
width. (See Dimensions and
weightsº on page 406 in Section 8
for information on your vehicle
overall length and width.)
Before driving, make sure the cargo
is securely fastened on the roof
luggage carrier.
Loading cargo on the roof luggage
carrier will make the center of the
vehicle gravity higher. Avoid high
speeds, sudden starts, sharp turns,
sudden braking or abrupt maneu-
vers, otherwise it may result in loss
of control or vehicle rollover due to
failure to operate this vehicle cor-
rectly.
Page 730 of 2572
'05 HIGHLANDER_U (L/O 0409)
288
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
If driving for a long distance, on
rough roads, or at high speeds,
stop the vehicle now and then dur-
ing the trip to make sure the cargo
remains in its place.
Do not exceed 45 kg (100 lb.) cargo
weight on the roof luggage carrier.
NOTICE
When loading the luggages, be careful
not to scratch the surface of the
moon roof.
Use a floor mat of the correct size.
If the floor carpet and floor mat have 2
holes, then they are designed for use with
locking clips. Fix the floor mat with lock-
ing clips into the holes in the floor carpet.CAUTION
Make sure the floor mat is properly
placed on the floor carpet. If the floor
mat slips and interferes with the
movement of the pedals during driv-
ing, it may cause an accident.
Floor mat
Page 731 of 2572

141P2-01
A94204
Timing Marks
Groove
Timing Marks
A53043
No. 1 Cylinder TDC/Compression
EX
IN
A52469
14-6
- ENGINE MECHANICALVALVE CLEARANCE (2AZ-FE)
2499 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
VALVE CLEARANCE (2AZ-FE)
ADJUSTMENT
1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER SPLASH SHIELD FRONT RH
3. REMOVE FRONT FENDER APRON SEAL RH
4. REMOVE ENGINE COVER SUB-ASSY NO.1
5. REMOVE IGNITION COIL ASSY
6. REMOVE SPARK PLUG
7. DISCONNECT VENTILATION HOSE
8. DISCONNECT VENTILATION HOSE NO.2
9. REMOVE CYLINDER HEAD COVER SUB-ASSY
(a) Remove the bolt and disconnect the engine wire harness
clamp.
(b) Remove the 8 bolts, 2 nuts, cylinder head cover and gas-
ket.
10. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing
mark 0 of the timing chain cover.
(b) Check that the timing marks of the camshaft timing gear
and sprocket are aligned with the timing marks of the
bearing cap No. 1 and No. 2 as shown in the illustration.
11. INSPECT VALVE CLEARANCE
HINT:
Inspect and adjust the valve clearance when the engine is cold.
(a) Check only the valve indicated on the left.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record valve clearance measurements that are out
of the specified range. These measurements will be
used later to determine the size of the adjustment
shim to be installed.
Page 732 of 2572

No. 4 Cylinder TDC/Compression
IN
EXA52470
Timing MarkPaint Mark
Timing Mark
Groove Paint Mark
A52471
A13325
- ENGINE MECHANICALVALVE CLEARANCE (2AZ-FE)
14-7
2500 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
Valve clearance (Cold):
ItemSpecified Condition
Intake0.19 to 0.29 mm (0.008 to 0.011 in.)
Exhaust0.30 to 0.40 mm (0.012 to 0.016 in.)
(b) Turn the crankshaft clockwise 1 revolution (360) and set
the No.4 cylinder to TDC/compression.
(c) Check only the valve indicated on the left.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record valve clearance measurements that are out
of the specified range. These measurements will be
used later to determine the size of the adjustment
shim to be installed.
Valve clearance (Cold):
ItemSpecified Condition
Intake0.19 to 0.29 mm (0.008 to 0.011 in.)
Exhaust0.30 to 0.40 mm (0.012 to 0.016 in.)
12. ADJUST VALVE CLEARANCE
NOTICE:
Be sure not to turn the crankshaft without the chain ten-
sioner.
(a) Turn the crankshaft clockwise 1 revolution (360) and set
the No. 1 cylinder to the TDC/compression.
(b) Place paint marks on the timing chain and camshaft tim-
ing gear sprocket.
(c) Remove the 2 bolts and chain tensioner.
Page 733 of 2572

FixLoosen
A52454
13 5 4 2A32636
A87614
13 5 4 2
A36526
A52474
14-8
- ENGINE MECHANICALVALVE CLEARANCE (2AZ-FE)
2501 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(d) Remove the No. 2 camshaft.
(1) Fix the camshaft with a wrench and then loosen the
sprocket bolt.
NOTICE:
Be careful not to damage the valve lifter.
(2) Uniformly loosen and remove the No. 2 camshaft's
10 bearing cap bolts in the sequence shown in the
illustration. Then remove the 5 bearing caps.
(3) Raise the No. 2 camshaft and remove it. Then re-
move the sprocket bolt.
(4) Remove the camshaft timing sprocket and the tim-
ing chain from the No. 2 camshaft.
(5) Remove the camshaft timing sprocket from the tim-
ing chain.
(e) Remove the camshaft.
(1) Uniformly loosen and remove the camshaft's 10
bearing cap bolts in the sequence shown in the il-
lustration. Then remove the 5 bearing caps.
(2) Remove the camshaft.
(f) Tie the timing chain with a string.
NOTICE:
Be careful not to drop anything inside the timing chain cov-
er.
(g) Remove the valve lifters.
Page 734 of 2572

A01082
- ENGINE MECHANICALVALVE CLEARANCE (2AZ-FE)
14-9
2502 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(h) Adjust the valve clearance.
(1) Using a micrometer, measure the thickness of the
removed lifter.
(2) Calculate the thickness of a new lifter so that the
valve clearance comes within the specified value.
AThickness of new lifter
BThickness of used lifter
CMeasured valve clearance
Valve clearance:
ItemSpecified Condition
IntakeA = B + (C - 0.24 mm (0.0094 in.))
ExhaustA = B + (C - 0.35 mm (0.0138 in.))
EXAMPLE: (Intake)
Measured valve clearance = 0.44 mm (0.0173 in.)
0.44 mm (0.0173 in.) - 0.24 mm (0.0094 in.) = 0.20 mm (0.0079 in.)
(Measured - Specification = Excess clearance)
Used shim measurement = 5.30 mm (0.2087 in.)
0.20 mm (0.0079 in.) + 5.30 mm (0.2087 in.) = 5.50 mm (0.2165 in.)
(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 5.50 mm (0.2165 in.) = Shim No. º50º
(3) Select a new lifter with a thickness as close as pos-
sible to the calculated values.
HINT:
Lifters are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm
(0.2260 in.).
Refer to valve lifter selection chart on the following 2
pages.
Page 735 of 2572

A77296
mm (in.)
Lifter
No.
ThicknessLifter
No.ThicknessLifter
No.Thickness
5.540 (0.2181)
5.560 (0.2189)
5.580 (0.2197)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260) 06
08
10
12
14
16
18
20
22
24
26
2830
32
34
36
38
40
42
44
46
48
50
5254
56
58
60
62
64
66
68
70
72
74 5.300 (0.2087)
5.320 (0.2094)
5.340 (0.2102)
5.360 (0.2110)
5.380 (0.2118)
5.400 (0.2126)
5.420 (0.2134)
5.440 (0.2142)
5.460 (0.2150)
5.480 (0.2157)
5.500 (0.2165)
5.520 (0.2173) 5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.220 (0.2055)
5.240 (0.2063)
5.260 (0.2071)
5.280 (0.2079)
Valve Lifter Selection Chart (Intake)
Intake valve clearance (Cold):
0.19 to 0.29 mm (0.008 to 0.011 in.)
EXAMPLE:
The 5.250 mm (0.2067 in.) lifter is installed, and the measured
clearance is 0.400 mm (0.0157 in.). Replace the 5.250 mm
(0.2067 in.) lifter with a new No. 42 lifter.
New Lifter Thickness
14-10
- ENGINE MECHANICALVALVE CLEARANCE (2AZ-FE)
2503 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
Page 736 of 2572

A77297
New lifter thickness mm (in.)
Lifter
No.
ThicknessLifter
No.ThicknessLifter
No.Thickness
5.540 (0.2181)
5.560 (0.2189)
5.580 (0.2197)
5.600 (0.2205)
5.620 (0.2213)
5.640 (0.2220)
5.660 (0.2228)
5.680 (0.2236)
5.700 (0.2244)
5.720 (0.2252)
5.740 (0.2260) 06
08
10
12
14
16
18
20
22
24
26
2830
32
34
36
38
40
42
44
46
48
50
5254
56
58
60
62
64
66
68
70
72
74 5.300 (0.2087)
5.320 (0.2094)
5.340 (0.2102)
5.360 (0.2110)
5.380 (0.2118)
5.400 (0.2126)
5.420 (0.2134)
5.440 (0.2142)
5.460 (0.2150)
5.480 (0.2157)
5.500 (0.2165)
5.520 (0.2173) 5.060 (0.1992)
5.080 (0.2000)
5.100 (0.2008)
5.120 (0.2016)
5.140 (0.2024)
5.160 (0.2031)
5.180 (0.2039)
5.200 (0.2047)
5.220 (0.2055)
5.240 (0.2063)
5.260 (0.2071)
5.280 (0.2079)
Valve Lifter Selection Chart (Exhaust)
Exhaust valve clearance (Cold):
0.30 to 0.40 mm (0.012 to 0.016 in.)
EXAMPLE:
The 5.340 mm (0.2102 in.) lifter is installed, and the measured
clearance is 0.440 mm (0.0173 in.). Replace the 5.340 mm
(0.2102 in.) lifter with a new No. 44 lifter.
- ENGINE MECHANICALVALVE CLEARANCE (2AZ-FE)
14-1 1
2504 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)