Introduction: Other Toyota Highlander I

ENGINE & TRANSAXLE SERIAL NUMBER

The engine serial number is stamped on the engine block and the transaxle serial number is stamped on the transaxle case. (Scheme 33)

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

1. Operations.
2. Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. See «VEHICLE LIFT AND SUPPORT LOCATIONS»(ref-174461-S41403210182005040500000).
3. PRECOATED PARTS: are bolts, nuts, etc. that are coated with a seal lock adhesive at the factory (Scheme 35): If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. NOTE: Perform the torque checking with the lower limit value of the torque tolerance. When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads. Precoated parts are indicated in the component illustrations. Depending on the seal lock agent applied, there may be a case where it is necessary to leave it for a specified time until it hardens.
4. GASKETS: When necessary, use a sealer on gaskets to prevent leaks.
5. BOLTS, NUTS AND SCREWS: Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
6. FUSES: When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating.
7. CLIPS: Removal procedures of typical clips are demonstrated in illustration. (Scheme 38)
8. Removal and installation of vacuum hoses: To disconnect vacuum hoses, pull off the end, not the middle of the hose. (Scheme 39) When disconnecting vacuum hoses, use tags to identify where they should be reconnected to. (Scheme 40) After completing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout. When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step-down adapter for adjustment. Once the hose has been stretched, it may leak air.
9. Using a torque wrench with an extension tool: When a SST or tool is combined with the torque wrench to extend its entire length, if you tighten until the reading of the torque wrench reaches the specified torque value, the actual torque becomes excessive. Unless otherwise noted, only the specified torque is described. In case of using SST or extension tool, calculate the reading of the torque wrench by the formula. Formula T1=T x L2/(L1 + L2)

FOR VEHICLES EQUIPPED WITH SRS AIRBAG & SEAT BELT PRETENSIONER

Highlander is equipped with an SRS (Supplemental Restraint System), such as the driver AIRBAG, front passenger AIRBAG, side AIRBAG, and seat belt pretensioner. Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint system, it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure described in this manual.

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

1. General notice: Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble codes become the most important source of information when troubleshooting. When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery. See «AIR BAG RESTRAINT SYSTEMS»(ref-150690). Work must be started after 90 seconds from the time the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery (The supplemental restraint system is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable from the battery, the SRS may deploy). When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by the each memory system. Then when work is finished, reset the clock and audio systems as before. To avoid erasing the memory of each memory system, never use a back-up power supply from another battery. Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front passenger's AIRBAG assembly and seat belt pretensioner should be inspected. See «AIR BAG RESTRAINT SYSTEMS»(ref-150690). Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. Before repairs, remove the AIRBAG sensor if shocks are likely to be applied to the sensor during repairs. Never disassemble and repair the AIRBAG sensor assembly, steering wheel pad, front passenger AIRBAG or seat belt pretensioner. If the AIRBAG sensor assembly, steering wheel pad, front passenger AIRBAG or seat belt pretensioner has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. Do not directly expose the AIRBAG sensor assembly, steering wheel pad, front passenger AIRBAG or seat belt pretensioner directly to hot air or flames. Use a volt/ohmmeter with high impedance (10 k/ohm minimum) for troubleshooting of the electrical circuit. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices. After work on the supplemental restraint system is completed, check the SRS warning light. See «AIR BAG RESTRAINT SYSTEMS»(ref-150690).
2. Spiral cable (in combination switch): the steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position (Scheme 42), otherwise cable disconnection and other troubles may result. Refer to STEERING COLUMN article concerning correct steering wheel installation.
3. Horn button assembly (with AIRBAG): When removing the horn button assembly or handling a new horn button, it should be placed with the pad top surface facing up. Placing it with the pad surface facing downward may lead to a serious accident if the AIRBAG inflates for some reason. In addition do not store a horn buttons on top of another one. Never measure the resistance of the AIRBAG squib. (This may cause the AIRBAG to deploy, which is very dangerous). Grease should not be applied to the horn button assembly and the pad should not be cleaned with detergents of any kind. Store the horn button assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. When using electric welding, first disconnect the AIRBAG connector (yellow color and 2 pins) under the steering column near the combination switch connector before starting work. When disposing of a vehicle or the horn button assembly alone, the AIRBAG should be deployed using an SST before disposal. See «AIR BAG RESTRAINT SYSTEMS»(ref-150690). Perform the operation in a safe place away from electrical noise.
4. Instrument panel AIRBAG assembly: Always store a removed or new instrument panel AIRBAG assembly with the AIRBAG deployment direction facing up. Placing the AIRBAG assembly with the AIRBAG deployment direction facing down could cause a serious accident if the AIRBAG deploys. Never measure the resistance of the AIRBAG squib. (This may cause the AIRBAG to deploy, which is very dangerous). Grease should not be applied to the instrument panel AIRBAG assembly and the AIRBAG door should not be cleaned with detergents of any kind. Store the AIRBAG assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. When using electric welding, first disconnect the AIRBAG connector (yellow color and 2 pins) installed on assembly before starting work. When disposing of a vehicle or the AIRBAG assembly alone, the AIRBAG should be deployed using an SST before disposal. See «AIR BAG RESTRAINT SYSTEMS»(ref-150690). Perform the operation in a safe place away from electrical noise.
5. Front seat AIRBAG assembly: Always store a removed or new front seat AIRBAG assembly with the AIRBAG inflating direction facing upward. Placing the AIRBAG assembly with the AIRBAG inflation direction facing downward could cause a serious accident if the AIRBAG inflates. Never measure the resistance of the AIRBAG squib (This may cause the AIRBAG to inflate, which is very dangerous.). Grease should not be applied to the front seat AIRBAG assembly and the AIRBAG door should not be cleaned with detergents of any kind. Store the AIRBAG assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise. When using electric welding, first disconnect the AIRBAG connector (2 yellow pins) installed on the assembly before starting work. When disposing of a vehicle or the side AIRBAG assembly alone, the AIRBAG should be inflated using an SST before disposal. See «AIR BAG RESTRAINT SYSTEMS»(ref-150690). Perform the operation in a safe place away from electrical noise.
6. Seat belt pretensioner: Never measure the resistance of the seat belt pretensioner. (This may cause the seat belt pretensioner to activate which is very dangerous). Never disassemble the seat belt pretensioner. Never install the seat belt pretensioner in another vehicle. Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F) and away from electrical noise without high humidity. When using electric welding, first disconnect the connector (yellow color and 2 pins) before starting work. When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensioner should be activated before disposal. See «AIR BAG RESTRAINT SYSTEMS»(ref-150690). Perform the operation in a safe place away from electrical noise. The seat belt pretensioner is hot after activation, so let it cool down sufficiently before the disposal. However, never apply water to the seat belt pretensioner.
7. AIRBAG sensor assembly: Never reuse the AIRBAG sensor assembly involved in a collision when the SRS has deployed. The connectors to the AIRBAG sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the AIRBAG sensor assembly is not mounted to the floor, it could cause undesired ignition of the supplemental restraint system. Work must be started after 90 seconds from the time the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery, even if only loosening the set bolts of the AIRBAG sensor assembly.
8. Wire harness and connector: The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it.

ELECTRONIC CONTROL

1. Removal and installation of battery terminal: Before performing electrical work, disconnect the battery negative (-) terminal cable beforehand so as to prevent burnt-out damage by short. When disconnecting and installing the terminal cable, turn the ignition switch and lighting switch OFF, and loosen the terminal nut completely. Perform these operations without twisting or prying the terminal. When the battery terminal is removed, all the memories of the clock, radio, DTCs, etc. will be erased. So before removing it, check them and note them down.
2. Handling of electronic parts: Do not open the cover or case of the ECU unless absolutely necessary. (if the IC terminals are touched, the IC may be destroyed by static electricity.) To disconnect electrical connectors, pull the connector itself, not the wires. Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. When cleaning the engine with steam, protect the electronic components, air filter and emission-related components from water. Never use an impact wrench to remove or install temperature switches or temperature sensors. When checking the continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending.

FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEM

1. Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic system.
2. Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle's electronic systems. For details about ECU and sensors locations, refer to the section on the applicable component.
3. Prevent the antenna feeder from getting entangled with the other wiring and keep the antenna feeder separate from the other wiring as much as possible.
4. Check that the antenna and feeder are correctly adjusted.
5. Do not install powerful mobile communications system.

FOR VEHICLES EQUIPPED WITH (TRAC) SYSTEM

Note. TRAC system OFF condition can be confirmed by the indication, "TRAC OFF", of the warning light in the combination meter.

Notices When Using 2-Wheel Drum Tester

When using a 2-wheel drum tester such as a speedometer tester, a combination tester of speedometer and brake, chassis dynamometer or else, always turn the TRAC system off via the TRAC OFF switch before measurement.

FOR VEHICLES EQUIPPED WITH (VSC) SYSTEM

Note. Confirm that the VSC warning light blinks. VSC system will be reset when the engine is restarted. Fasten the vehicle with lock chains.

Scheme 49

1. Notices When Using Drum Tester: When using a drum tester, be sure to start the engine with the ignition OFF, and connect SST to the terminals TS and CG of the DLC3 before measurement in order to prohibit the VSC operation. (Scheme 50) SST 09843-18040
2. Notices Of Related Operations To VSC: Do not carry out unnecessary installation and removal, because it might disorder the adjustment of related parts to VSC. Be sure to carry out the preparation for operation and the confirmation of operation completion, in accordance with the instruction of the text, when the related operations to VSC are performed.

WHEN SERVICING FULL-TIME 4WD VEHICLES

1. Measuring points for speedometer testing: Place the front wheels onto rollers. Set the rear wheels free by free rollers or rigid racks. Fasten the vehicle with the lock chain. Start the engine, and then measure the vehicle speed by increasing the speed gradually in the "D" range. After the measurement completion, decrease the vehicle speed by brake gradually, and then stop the vehicle.
2. Measuring Points for brake tester: Place the wheels to be measured (front or rear) onto the rollers. Shift the shift lever into neutral. Perform the measurement by driving the tester onto rollers.
3. Measuring points for on-vehicle balancer: Jack up all 4 wheels with 2 post lift. Fasten the vehicle by setting 2 jack stands in the bottom of suspension arms tip of the front or rear wheel to be measured. Support the vehicle with rigid racks so that vehicle will not lean in the vehicles front or rear direction. Release the parking brake. Check that no dragging force exists by turning each wheel by hand. Set the wheel balancers. Measurement should be done by using both of engine drive and wheel balancer roller drive.

FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER

WHEN TOWING FULL-TIME 4WD VEHICLES

1. Tow the vehicles with the 4 wheels touching the ground or the 4 wheels held up. In case that an abnormality exists in the chassis and drive train, tow the vehicle with the 4 wheels held up.
2. Never tow the vehicle with either condition of the front wheels only or the rear only held up. (Scheme 52)
3. Towing the vehicle should be done by one of the towing methods shown. (Scheme 51)
4. If the vehicle has a problem in the chassis or drive train, use the wheel type truck.

Towing Vehicle

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

1. Notice about vehicle condition when jacking up: As a rule, the vehicle must be unloaded when jacking up. Never jack up or lift up the vehicle loaded with heavy weight. When removing any parts of heavy weight like the engine and transmission, the center of gravity of the vehicle moves. Place a balance weight so as to keep it from rolling, or hold the jacking support location using the mission jack.
2. Notice for using 4 post lift: Follow the instruction manual for safe operation. Do not damage tires or wheels with a free wheel beam. Using a wheel stopper, fix the vehicle.
3. Notice for using jack and safety stand: Work in the flat place using a wheel stopper at all times. Use a safety stand with a rubber attachment, as shown in the illustration. (Scheme 53) Support the specified location with the jack and safety stand accurately. When jacking up the front wheels, release the parking brake and place wheel stoppers only behind the rear wheels. When jacking up the rear wheels, place wheel stoppers only in front of the front wheels. Do not work or leave the vehicle supported only by a jack. Be sure to support the vehicle with the safety stand When jacking up only the front wheels or only the rear wheels, place wheel stoppers to both sides of the wheels. When jacking down the vehicle with its front wheels jacked up, release the parking brake and place wheels stoppers only in front of the rear wheels. When jacking down the vehicle with its rear wheels jacked up, place wheel stoppers only behind the front wheels.
4. Notice for using swing arm type lift: Follow the instruction manual of the lift for a safety operation. Use a cradle with a rubber attachment, as shown in the illustration. (Scheme 55) Set in the vehicle so as to make its center of gravity as closer as the center of the lift. ("L" becomes short). Make the vehicle horizontal by adjusting the height of the cradle, and match the groove of the cradle and the safety stand support location accurately. Be sure to lock the swing arm during the operation. Lift the vehicle up until the tires float and shake the vehicle to make sure that the vehicle is stable.
5. Notice for using plate type lift: Follow the instruction manual of the lift for a safety operation. Use a plate lift attachment. Be sure to set the vehicle to the specified position. Lift the vehicle up until the tires float a bit and shake the vehicle to make sure that the vehicle is stable.

Customer Problem Analysis

In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred.

Important Points in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases. As much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in most articles for each system for your use.

1. What: Vehicle model, system name.
2. When: Date, time, occurrence frequency.
3. Where: Road conditions.
4. Under what conditions? Running conditions, driving conditions, weather conditions.
5. How did it happen? Problem symptoms.

Scheme 56