Page 737 of 2572

Paint Mark
Timing Marks
A52456
53 1 2 4
Bearing Cap No. 1Bearing Cap No. 3A52457
Timing MarkPaint MarkA53011
A52473
1 3 542
Bearing Cap No. 2 Bearing Cap No. 3
A52458
14-12
- ENGINE MECHANICALVALVE CLEARANCE (2AZ-FE)
2505 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(i) Install the camshaft.
(1) Install the timing chain on the camshaft timing gear,
with the paint mark aligned with the timing marks on
the camshaft timing gear.
(2) Examine the front marks and numbers of the 5 bear-
ing caps and install them. Then install the 10 bear-
ing cap bolts. Uniformly tighten the bolts in the se-
quence shown in the illustration.
Torque:
30 NVm (301 kgfVcm, 22 ftVlbf) for bearing cap No. 1
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for bearing cap No. 3
(j) Install the No. 2 camshaft.
(1) Put the No. 2 camshaft on the cylinder head with the
paint mark of the chain aligned with the timing mark
on the camshaft timing sprocket.
(2) Raise the No. 2 camshaft and temporarily tighten
the sprocket bolt.
(3) Examine the front marks and numbers of the 5 bear-
ing caps and install them. Then install the 10 bear-
ing cap bolts. Uniformly tighten the bolts in the se-
quence shown in the illustration.
Torque:
30 NVm (301 kgfVcm, 22 ftVlbf) for bearing cap No. 2
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for bearing cap No. 3
Page 738 of 2572
TightenFix
A52459
Paint Mark7 Links
Timing Mark
Groove Paint Mark
Timing Marks
A52460
Raise
PinHook
Push
A52461
Engine
Front
A52462
- ENGINE MECHANICALVALVE CLEARANCE (2AZ-FE)
14-13
2506 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(4) Fix the camshaft with a wrench, then tighten the
sprocket bolt.
Torque: 54 NVm (551 kgfVcm, 40 ftVlbf)
NOTICE:
Be careful not to damage the valve lifter.
(k) Check that the timing chain paint marks are aligned with
the camshaft timing sprocket timing mark and the cam-
shaft timing gear timing mark. Also check the alignment
of the pulley groove and chain cover timing mark.
(l) Install the chain tensioner.
(1) Release the ratchet pawl, fully push in the plunger
and apply the hook to the pin so that the plunger
cannot spring out.
(2) Install a new gasket and the chain tensioner with the
2 nuts.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
NOTICE:
When installing the tensioner, set the hook again if the
hook releases the plunger.
Page 739 of 2572

A93972
Disconnect
HookPin
Turn
A93973
Plunger
Push
Turn
Seal Packing
A53051
NutNutA61989
A
B A
A
A
A
AB 14-14
- ENGINE MECHANICALVALVE CLEARANCE (2AZ-FE)
2507 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(3) Turn the crankshaft counterclockwise, and discon-
nect the plunger knock pin from the hook.
(4) Turn the crankshaft clockwise, and check that the
slipper is pushed by the plunger.
13. INSTALL CYLINDER HEAD COVER SUB-ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to 2 locations as shown in the illustra-
tion.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the cylinder head cover within 5 minutes after
applying seal packing.
Do not start the engine for at least 2 hours after instal-
ling the cylinder head cover.
(c) Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque:
11 NVm (112 kgfVcm, 8 ftVlbf) for nut
11 NVm (112 kgfVcm, 8 ftVlbf) for bolt A
14 NVm (143 kgfVcm, 10 ftVlbf) for bolt B
14. INSTALL SPARK PLUG
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
15. INSTALL IGNITION COIL ASSY
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
16. INSTALL FRONT WHEEL RH
17. CHECK FOR ENGINE COOLANT LEAKS (See page 16-6)
Page 740 of 2572
*The titles given inside the components are the names of the terminals (terminal codes) and are not treated as being
abbreviations.
2005 HIGHLANDER (EWD592U)
17
ABBREVIATIONS D
ABBREVIATIONS
The following abbreviations are used in this manual.
2WD = Two Wheel Drive Vehicles
A/C = Air Conditioning
A/T = Automatic Transaxle
ABS = Anti-Lock Brake System
ACIS = Acoustic Control Induction System
ACM = Active Control Engine Mount
BEAN = Body Electronics Area Network
CAN = Controller Area Network
EC = Electrochromic
ECU = Electronic Control Unit
ESA = Electronic Spark Advance
EVAP = Evaporative Emission
IC = Integrated Circuit
J/B = Junction Block
LH = Left-Hand
O/D = Overdrive
R/B = Relay Block
RH = Right-Hand
SFI = Sequential Multiport Fuel Injection
SRS = Supplemental Restraint System
SW = Switch
TEMP. = Temperature
TRAC = Traction Control
VSC = Vehicle Stability Control
VSV = Vacuum Switching Valve
VVT = Variable Valve Timing
w/ = With
w/o = Without
Page 741 of 2572
F46304
Combination Meter
Passenger Side J/BABS C11
Instrument Panel J/BSkid Control ECU with Actuator
I15
Ignition SW
F7
FL BlockC11 IF2
IL1 IC4 S27
S27 S27 4E
4H 4JJ6
J/C
IC4
IC1 1A
1C 1D
1G
1C 1C ECU-IG
IGN
AM1IG1 4M
IG2AM1
AM2WA
IG1
GND1
EA EB ALT
AM2
J4
J/C FL MAIN
Battery1
24 6
7 9
10 13
1729
4
446
4
62
10
32 12
12
1 E P W SB R-L
P
ESB
GRB-R
G
GR
W
Y
L-Y WB
W-B Y
W
AW-B 167 10
1
6 05-840
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
1030 Author: Date:
ABS WARNING LIGHT CIRCUIT (REMAINS ON)
CIRCUIT DESCRIPTION
During DTC read by SST (CHECK WIRE), if the ABS warning light remains on, troubleshoot by following
this inspection flow.
WIRING DIAGRAM
05CDG-1 1
Page 742 of 2572
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-841
1031 Author: Date:
INSPECTION PROCEDURE
1 CHECK DTC
(a) Is DTC output for ABS?
Standard:
DTC is not outputA
DTC is outputB
B REPAIR CIRCUIT INDICATED BY OUTPUT
CODE
A
2 INSPECT CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY
CONNECTED
NG CONNECT CONNECTOR TO ECU
OK
3 INSPECT BATTERY
(a) Check the battery voltage.
Standard:
Tester ConnectionSpecified Condition
Battery terminal
((+) - (-))11 to 14 V
NG INSPECT CHARGING SYSTEM
OK
Page 743 of 2572
G24767
GND1IG1
Skid Control ECU
(harness side connector)
S27
05-842
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
1032 Author: Date:
4 INSPECT SKID CONTROL ECU TERMINAL VOLTAGE(IG1 TERMINAL)
WHEN USING HAND-HELD TESTER:
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine.
(c) Select the DATA LIST mode on the hand-held tester.
(d) Read the voltage condition output from the ECU displayed on the hand-held tester.
ItemMeasurement Item /
Range (Display)Normal Condition
IG VOLTAGEECU power supply voltage /
TOO LOW / NORMALNORMAL: 9.5 V or over
TOO LOW: Below 9.5 V
OK:
ºNormalº is displayed.
WHEN NOT USING HAND-HELD TESTER:
(a) Disconnect the skid control ECU connector.
(b) Turn the ignition switch ON position.
(c) Measure the voltage according to the value(s) in the table
below.
Standard:
Tester ConnectionSpecified Condition
S27-46 (IG1) - S27-32 (GND1)11 to 14 V
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
Page 744 of 2572

F46286
Skid Control ECU Front View
S27WA
Combination Meter
(harness side view)
C11
G24767
Skid Control ECU
(harness side connector)S27
GND1
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-843
1033 Author: Date:
5 CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - COMBINATION
METER)
(a) Disconnect the skid control ECU connector and combina-
tion meter connector.
(b) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSpecified Condition
C11-17 - S27-29 (WA)Below 1 W
(c) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSpecified Condition
S27-29 (WA) - Body ground10 kW or higher
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
6 CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - BODY GROUND)
(a) Disconnect the skid control ECU connector.
(b) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSpecified Condition
S27-32 (GND1) - Body groundBelow 1 W
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37)