Introduction (Except Hybrid): Overview Toyota Highlander II

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1. GENERAL DESCRIPTION This article is written in accordance with SAE J2008. Repair operations can be separated mainly in the following 3 processes: Diagnosis Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting Final Inspection The following procedures are omitted from this article. However, these procedures must be performed. Use a jack or lift to perform operations. Clean all removed parts. Perform a visual check before and after performing any work.
2. PREPARATION Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending on the repair procedure. Be sure to use SST and SSM when they are required and follow the working procedure properly. A list of SST and SSM is in «PREPARATION»(/toyota/highlander/ii-2007-2010/remont/communication-devices/#preparation-except-hybrid) .
3. REPAIR PROCEDURES A component graphic is placed under the title where necessary. Non-reusable parts, grease application areas, precoated parts and torque specifications are noted in the component graphics. The following graphic is an example. Torque specifications, grease application areas and non-reusable parts are emphasized in the procedures. HINT: There are cases where such information can only be explained by using a graphic. In these cases, torque, oil and other information are described in the graphic. Only items with key points are described in the text. What to do and other details are explained using graphics next to the text. Both the text and graphics are accompanied by standard values and notices. GENERAL SPECIFICATIONS Graphic What to do and where to do it Task heading What work will be performed Explanation text How to perform the task Also has information such as specifications and warnings, which are written in boldface text Graphics of similar vehicle models are sometimes used. In these cases, minor details may be different from the actual vehicle. Procedures are presented in a step-by-step format.
4. SERVICE SPECIFICATIONS SPECIFICATIONS are presented in boldface text throughout the manual. The specifications are also found in «SERVICE SPECIFICATIONS»(ref-290694).
5. TERM DEFINITIONS TERM DEFINITIONS TABLE CAUTION Possibility of injury to you or other people. NOTICE Possibility of damage to components being repaired. HINT Provides additional information to help you perform repairs.
6. INTERNATIONAL SYSTEM OF UNITS The units used in this article comply with the International System of Units (SI UNIT) standard. Units from the metric system and the English systems are also provided. Example: Torque: 30 N*m (310 kgf*cm, 22 ft.*lbf)

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1. VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the vehicle body and on the certification label as shown below. A: Vehicle Identification Number B: Certification Label
2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL NUMBER The engine serial number is stamped on the cylinder block of the engine as shown below. A: 2GR-FE Engine Serial Number The transaxle serial number is stamped on the case as shown below. A: U151E, U151F Transaxle Serial Number

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1. BASIC REPAIR HINT HINTS ON OPERATIONS JACKING UP AND SUPPORTING VEHICLE Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations. PRECOATED PARTS Precoated parts are bolts and nuts that are coated with a seal lock adhesive at the factory. If a precoated part is retightened, loosened or moved in any way, it must be recoated with the specified adhesive. When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriately to that part. Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden. GASKETS When necessary, use a sealer on gaskets to prevent leaks. BOLTS, NUTS AND SCREWS Carefully follow all the specifications for tightening torques. Always use a torque wrench. FUSES When inspecting a fuse, check that the wire of the fuse is not broken. When replacing fuses, be sure that the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating. CLIPS The removal and installation methods of typical clips used for vehicle body parts are shown in the table below. HINT: If clips are damaged during work, always replace the damaged clips with new ones. CLAWS The removal and installation methods of typical claws used for vehicle body parts are shown in the table below. HINT: If claws are damaged during a procedure, always replace the cap or cover that has damaged claws with a new one. HINGE, GUIDE, CLAMP AND PIN ETC. The removal and installation methods of typical hinge, guide, clamp and pin used for vehicle body parts are shown in the table below. HINT: If clamps are damaged during a procedure, always replace the cap or cover that has damaged clamps with a new one. REMOVAL AND INSTALLATION OF VACUUM HOSES To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may damage the hose. When disconnecting vacuum hoses, use tags to identify where they should be reconnected. After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout. When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, air may leak. Use a step-down adapter if necessary. TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench. Formula: T' = L2/(L1 + L2) * T FORMULA TABLE T' Reading of torque wrench {N*m (kgf*cm, ft.*lbf)} T Torque {N*m (kgf*cm, ft.*lbf)} L1 Length of SST or extension tool {cm (in.)} L2 Length of torque wrench {cm (in.)} NOTE: If an extension tool or SST is combined with a torque wrench and the wrench is used to tighten to a torque specification in this article, the actual torque will be excessive and parts will be damaged.
2. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER This vehicle is equipped with a Supplemental Restraint System (SRS). CAUTION: Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury. Furthermore, if a mistake is made when servicing SRS, it is possible that the SRS may fail to operate properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following section carefully. GENERAL NOTICE As malfunctions of the SRS are difficult to confirm, the Diagnostic Trouble Codes (DTCs) become the most important source of information when troubleshooting. When troubleshooting the SRS, always check the DTCs before disconnecting the battery. Work must be started at least 90 seconds after the ignition switch is turned off and after the cable is disconnected from the negative (-) battery terminal. The SRS is equipped with a back-up power source. If work is started within 90 seconds after turning the ignition switch off and disconnecting the cable from the negative (-) battery terminal, the SRS may deploy. When the cable is disconnected from the negative (-) battery terminal, clock and audio system memory is erased. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before. CAUTION: Never use a back-up power source (battery or other) to avoid erasing the system memory. The back-up power source may inadvertently power the SRS and cause it to deploy. In minor collisions where the SRS does not deploy, the steering pad, front passenger airbag assembly, driver side knee airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and front seat outer belt assembly should be inspected before further use of the vehicle. Never use the SRS parts from another vehicle. When replacing parts, use new parts. Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensor during repairs. Never disassemble and attempt to repair all airbag sensor assemblies and all airbag assemblies. Steering pad Front passenger airbag assembly Driver side knee airbag assembly Front seat side airbag assembly Curtain shield airbag assembly Front seat outer belt assembly Replace the airbag sensor assemblies and the airbag assemblies if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present. Do not directly expose the airbag sensor assemblies or airbag assemblies to hot air or flames. Use a voltmeter/ohmmeter with high impedance (minimum = 10 kohms) for troubleshooting electrical circuits. Information labels are attached to the SRS components. Follow the instructions on the labels. After work on the SRS is completed, check the SRS warning light. SPIRAL CABLE The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel (See «INSTALLATION»(ref-290696-S09470639352008071700000) ). STEERING PAD Always place a removed or new steering pad surface upward as shown below. Placing the steering pad of the pad surface facing down could cause a serious accident if the airbag deploys. Also, do not place anything on top of the steering pad. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury. Grease or detergents of any kind should not be applied to the steering pad. Store the steering pad in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. When disposing of the vehicle or the steering pad by itself, the airbag should be deployed using SST before disposal (See «DISPOSAL»(/toyota/highlander/ii-2007-2010/remont/airbag/#supplemental-restraint-system-except-hybrid) ). Deploy the airbag in a safe place away from electrical noise. FRONT PASSENGER AIRBAG ASSEMBLY Always place a removed or new front passenger airbag assembly with the pad surface facing upward as shown below. 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 could cause serious injury. Grease or detergents of any kind should not be applied to the front passenger airbag assembly. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. When disposing of the vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See «DISPOSAL»(/toyota/highlander/ii-2007-2010/remont/airbag/#supplemental-restraint-system-except-hybrid) ). Deploy the airbag in a safe place away from electrical noise. DRIVER SIDE KNEE AIRBAG ASSEMBLY Always place a removed or new driver side knee airbag assembly with the airbag deployment direction facing upward. Placing the airbag assembly with the airbag deployment direction facing downward 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 could cause serious injury. Grease or detergents of any kind should not be applied to the driver side knee airbag assembly. Store the driver side knee airbag assembly where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. When disposing of a vehicle or driver side knee airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See «DISPOSAL»(/toyota/highlander/ii-2007-2010/remont/airbag/#supplemental-restraint-system-except-hybrid) ). Deploy in a safe place, away from electrical noise. FRONT SEAT SIDE AIRBAG ASSEMBLY Always place a removed or new front seat side airbag assembly with the airbag deployment direction facing up. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury. Grease or detergents of any kind should not be applied to the front seat side airbag assembly. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See «DISPOSAL»(/toyota/highlander/ii-2007-2010/remont/airbag/#supplemental-restraint-system-except-hybrid) ). Deploy the airbag in a safe place away from electrical noise. CURTAIN SHIELD AIRBAG ASSEMBLY Always place a removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place. CAUTION: The plastic bag is not reusable. NOTE: Never disassemble the curtain shield airbag assembly. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury. Grease or detergents of any kind should not be applied to the curtain shield airbag assembly. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See «DISPOSAL»(/toyota/highlander/ii-2007-2010/remont/airbag/#supplemental-restraint-system-except-hybrid) ). Deploy the airbag in a safe place away from electrical noise. FRONT SEAT OUTER BELT ASSEMBLY (SEAT BELT PRETENSIONER) Never measure the resistance of the front seat outer belt assembly. This may cause the pretensioner of the front seat outer belt assembly to activate, which could cause serious injury. Never disassemble the front seat outer belt assembly. Never install the front seat outer belt assembly on another vehicle. Store the front seat outer belt assembly in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise. When using electric welding anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring. When disposing of a vehicle or the front seat outer belt assembly unit by itself, the front seat outer belt assembly should be activated before disposal (See «DISPOSAL»(ref-290708-S15590581882008071700000) ). Activate the front seat outer belt assembly in a safe place away from electrical noise. As the front seat outer belt assembly is hot after being activated, allow some time for it to cool down sufficiently before disposal. Never apply water to cool down the front seat outer belt assembly. Grease, detergents, oil or water should not be applied to the front seat outer belt assembly. CENTER AIRBAG SENSOR ASSEMBLY Never reuse a center airbag sensor assembly that has been involved in a collision where the SRS has deployed. The connectors to the center airbag sensor assembly should be connected or disconnected with the sensor placed on the floor. If the connectors are connected or disconnected while the center airbag sensor assembly is not placed on the floor, the SRS may activate. Work must be started at least 90 seconds after the ignition switch is turned off and the cable is disconnected from the negative (-) battery terminal, even if only loosening the set bolts of the center airbag sensor assembly. WIRE HARNESS AND CONNECTOR All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken, repair or replace it.
3. ELECTRONIC CONTROL REMOVAL AND INSTALLATION OF BATTERY TERMINAL NOTE: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal. Before performing electronic work, disconnect the cable from the negative (-) battery terminal to prevent component and wire damage caused by accidental short circuits. When disconnecting the cable, turn the ignition switch and headlight dimmer switch off and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then disconnect the cable. Clock settings, radio settings, audio system memory, DTCs and other data are erased when the cable is disconnected from the negative (-) battery terminal. Write down any necessary data before disconnecting the cable. 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 rendered inoperative by static electricity. Do not pull the wires when disconnecting electronic connectors. Pull the connector itself. Do not drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced. 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 measuring the resistance between terminals of a wire connector, insert the tester probe carefully to prevent terminals from bending.
4. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources. Never work in a pit or near a pit as vaporized fuel will collect in those places. REMOVING AND INSTALLING FUEL SYSTEM PARTS Prepare a fire extinguisher before starting the operation. To prevent static electricity, install a ground wire to the fuel changer, vehicle and fuel tank, and do not spray the surrounding area with water. Be careful when performing work in this area, as the work surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread, and possibly create a fire hazard. Avoid using electric motors, working lights and other electric equipments that can cause sparks or high temperatures. Avoid using iron hammers as they may create sparks. Dispose of fuel-contaminated cloth separately using a fire resistant container.
5. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS If any metal particles enter inlet system parts, this may damage the engine. When removing and installing inlet system parts, cover the openings of the removed parts and engine openings. Use adhesive tape or other suitable materials. When installing inlet system parts, check that no metal particles have entered the engine or installed parts.
6. HANDLING OF HOSE CLAMPS Before removing the hose, check the clamp position so that it can be reinstalled in the same position. Replace any deformed or dented clamps with new ones. When reusing a hose, attach the clamp on the clamp track portion of the hose. For a spring type clamp, you may want to spread the tabs slightly after installation by pushing in the direction of the arrows as shown below.
7. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS Install the antenna far away from the ECU and sensors of the vehicle electronic systems as possible. Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details about ECU and sensor locations, refer to the section on the applicable components. Keep the antenna and feeder separate from other wirings as much as possible. This will prevent signals sent from the communication equipment from affecting vehicle equipment and vice-versa. Check that the antenna and feeder are correctly adjusted. Do not install any high-powered mobile communication system.
8. WHEN SERVICING FULL-TIME 4WD VEHICLES MEASURING POINTS FOR SPEEDOMETER TESTER NOTE: Tester with a function of load setting for only two wheels cannot be used. Inspection should be done in the front wheels. Do not start, accelerate nor decelerate the vehicle suddenly. Maximum vehicle speed must be below 60 km/h (37 mph) (when using free roller, it must be below 50 km/h (31 mph)). Driving time should be within 1 minute. Place the front wheels onto the 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 braking gradually, and then stop the vehicle. MEASURING POINTS FOR BRAKE TESTER NOTE: Tester with a function of load measurement cannot be used. High-speed braking cannot be performed. Place the wheels to be measured (front or rear) onto the rollers. Shift the lever into neutral. Perform the measurement by driving the tester rollers. MEASURING POINTS FOR ON-VEHICLE BALANCER Jack up all 4 wheels with 2 post lifts. Fasten the vehicle by setting 2 pick-up stands in the bottom of suspension arm's tip of the front wheels or rear wheels to be measured. Support the vehicle with rigid racks so that vehicle will not lean in any direction. Release the parking brake. Check that there is no dragging force exists when turning each wheel by hand. Set the wheel balancers. Measurement should be done by using both of engine drive and wheel balancer roller drive. NOTE: Start the engine, and then increase the vehicle speed gradually in the D range. Do not accelerate nor decelerate suddenly. Deceleration should be done by braking gradually. Take special care that the vehicle does not move. Measurement should be done quickly.
9. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRAC) AND VEHICLE STABILITY CONTROL (VSC) SYSTEMS When testing with a 2-wheel drum tester such as a speedometer tester, a combination tester for the speedometer and brake, a chassis dynamometer, or when jacking up the front wheels and turning the wheels, perform the following procedure to enter the inspection mode and stop the TRAC and VSC systems. Enter inspection mode to disable TRAC and VSC control when using a chassis dynamometer. HINT: The vehicle may move unexpectedly out of the dynamometer because of TRAC and VSC operations. Pressing the VSC OFF switch (for vehicles with the VSC OFF switch) does not disable TRAC and VSC operation completely. NOTE: Make sure that the VSC warning light is blinking. Secure the vehicle with the lock chain for safety. Activating inspection mode (Not using Techstream) HINT: Perform steps "D" to "H" within 30 seconds. Perform steps "F" and "G" within 15 seconds each. Ensure that the ignition switch is off and the engine is stopped (Step "A"). Make sure that the shift lever is in the P position (Step "B"). Start the engine (Step "C"). Apply the parking brake by pulling the parking brake lever (Step "D"). Depress and release the brake pedal twice (Step "E"). While holding the brake pedal down, release and apply the parking brake twice (Step "F"). With the parking brake applied, depress and release the brake pedal twice (Step "G"). Check if the SLIP indicator light comes on (Step "H"). HINT: If the SLIP indicator light does not come on in step "H", repeat the steps from "A" to "H". Turning the ignition switch offends inspection mode. Activating inspection mode (Using Techstream) Ensure that the ignition switch is off and the engine is stopped (Step "A"). Make sure that the shift lever is in the P position (Step"B"). Connect Techstream to the DLC3 (Step "C"). Start the engine (Step "D"). Turn the Techstream main switch on (Step "E"). Select the following menu items: ABS/INSPECTION MODE (Step "F"). Check that the SLIP indicator light come on (Step "G"). HINT: If the SLIP indicator light does not come on in step "G", repeat the steps from "A" to "G". Turning the ignition switch off ends inspection mode.
10. WHEN TOWING FULL-TIME 4WD VEHICLES Use one of the following methods to tow the vehicle. If the vehicle has trouble with the chassis or drive train, use method 1 (flat bed truck). NOTE: Do not use any towing method other than those (Scheme 34) The following towing methods shown are dangerous and can damage the vehicle, so do not use them.
11. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER CAUTION: If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause overheating and create a fire hazard. To prevent this, observe the following precautions: Use only unleaded gasoline. Avoid idling the engine for more than 20 minutes. Avoid performing unnecessary spark jump tests. Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible. While testing, never race the engine. Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible. Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter.
12. EXPRESSIONS OF IGNITION SWITCH The type of ignition switch used on this model differs according to the specifications of the vehicle. The expressions listed in the following table are used in this section. IGNITION SWITCH REFERENCE TABLE Switch Type Ignition Switch (position) Engine Switch (condition) Expression Ignition switch off LOCK Off Ignition switch on (IG) ON On (IG) Ignition switch on (ACC) ACC On (ACC) Engine start START Start
13. INSPECTION AND ADJUSTMENT OF JOINT ANGLE DURING REMOVAL AND INSTALLATION OF PROPELLER SHAFT (4WD) When performing operations which involve the removal and installation of the propeller shaft, always check the joint angle. Make adjustments if necessary (See «INSTALLATION»(/toyota/highlander/ii-2007-2010/remont/driveshaft-universal-joints/#propeller-shaft-except-hybrid) ).

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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 heavyweight items. When removing any heavyweight components like the engine or transaxle, the center of gravity of the vehicle moves. Place a balance weight so as to keep the vehicle from rolling, or support the jack position using the transmission 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 wheel stoppers, secure the vehicle.
3. NOTICE FOR USING JACK AND SAFETY STAND Work in a flat place using wheel stoppers at all times. Use safety stands with a rubber attachments, as shown below. Securely support the specified locations with a jack and safety stands. 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 a safety stand. When jacking up only the front wheels or only the rear wheels, place wheel stoppers on both sides of the wheels that contact ground. When lowering the vehicle with its front wheels jacked up, release the parking brake and place wheel stoppers only in front of the rear wheels. When lowering 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 safe operation. Use a cradle with a rubber attachment, as shown below. Set in the vehicle so as to make its center of gravity as close as possible to the center of the lift. Place the vehicle horizontally 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 are off the ground, 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 safe operation. Use a plate lift attachment. Be sure to set the vehicle to the specified position. VEHICLE LIFTING SPECIFIED POSITION TABLE Right and left set position Place the vehicle over the center of the lift. Front and rear set position Align the cushion ends of the plate with the attachment lower ends (A and C). Align the attachment upper end (B) with the rocker flange front side notch. Lift the vehicle up until the tires are slightly off the ground a bit, and shake the vehicle to make sure that the vehicle is stable.

GENERAL INFORMATION

A large number of ECU controlled systems are used in this vehicle. In general, ECU controlled systems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures only involve inspecting the ECU controlled system's circuits one by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective troubleshooting, accurate diagnoses and necessary repairs.

FOR USING Techstream*

HINT

*: Techstream is the name for the diagnostic tester in North America.

1. Before using Techstream, read the operator's manual thoroughly.
2. If Techstream cannot communicate with the ECU controlled systems when Techstream is connected to the DLC3 with the ignition switch on (IG) and Techstream turned on, there is a problem on the vehicle side or Techstream side. If communication is normal when Techstream is connected to another vehicle, inspect the diagnosis data link line (Bus (+) line) or ECU power circuit of the vehicle. If communication is still not possible when Techstream is connected to another vehicle, the problem is probably in Techstream itself. Perform the Self Test procedures outlined in the Techstream operator's manual.

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1. DESCRIPTION Each system data and the Diagnostic Trouble Codes (DTCs) can be read from the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use Techstream to check for malfunctions and perform repairs.
2. CHECK DLC3 The vehicle's ECU uses the ISO 15765-4 communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. CONNECTOR TERMINAL REFERENCE TABLE Symbols Terminal No. Names Reference Terminal Results Condition SIL 7 Bus "+" line 5 - Signal ground Pulse generation During transmission CG 4 Chassis ground Body ground 1 ohms or less Always SG 5 Signal ground Body ground 1 ohms or less Always BAT 16 Battery positive Body ground 1 ohms or less Always CANH 6 CAN "High" line 14 - CANL 54 to 69 ohms Ignition switch off* Battery positive 6 kohms or higher Ignition switch off* 4 - CG 200 ohms or higher Ignition switch off* CANL 14 CAN "Low" line Battery positive 6 kohms or higher Ignition switch off* 4 - CG 200 ohms or higher Ignition switch off* NOTE: (1) Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, any other switches, or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: If communication is normal when Techstream is connected to another vehicle, inspect the DLC3 on the original vehicle. If communication is still not possible when Techstream is connected to another vehicle, the problem is probably in the tester itself. Consult the Service Department listed in Techstream's instruction manual.

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1. BASIC INSPECTION WHEN MEASURING RESISTANCE OF ELECTRONIC PARTS Unless otherwise stated, all resistance measurements are standard values measured at an ambient temperature of 20°C (68°F). Resistance measurements may be inaccurate if measured at high temperatures, i.e. immediately after the vehicle has been running. Measurements should be made after the engine has cooled down. HANDLING CONNECTORS When disconnecting a connector, first squeeze the mating connector housing halves tightly together to release the lock, and then press the lock claw and separate the connector. When disconnecting a connector, do not pull on the harnesses. Grasp the connector directly and separate it. Before connecting a connector, check that there are no deformations, damage, looseness or missing terminals. When connecting a connector, press firmly until it locks with a "click" sound. If checking a connector with a TOYOTA electrical tester, check the connector from the backside (harness side) using a mini test lead. NOTE: As a waterproof connector cannot be checked from the backside, check it by connecting a sub-harness. Do not damage the terminals by moving the inserted tester needle. CHECKING CONNECTORS Checking when a connector is connected: Squeeze the connector together to confirm that they are fully connected and locked. Checking when a connector is disconnected: Check by pulling the wire harness lightly from the backside of the connector. Look for unlatched terminals, missing terminals, loose crimps or broken conductor wires. Check visually for corrosion, metallic or foreign matter and water, and bent, rusted, overheated, contaminated, or deformed terminals. Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a female terminal, and check for ample tension when inserting and after full engagement. NOTE: When testing a gold-plated female terminal, always use a gold-plated male terminal. REPAIR METHOD OF CONNECTOR TERMINAL If there is any foreign matter on the terminal, clean the contact point with compressed air or a cloth. Never rub the contact point using sandpaper as the plating may come off. If there is abnormal contact pressure, replace the female terminal. If the male terminal is gold-plated (gold color), use a gold-plated female terminal; if it is silver-plated (silver color), use a silver-plated female terminal. Damaged, deformed, or corroded terminals should be replaced. If the terminal does not lock into the housing, the housing may have to be replaced. HANDLING OF WIRE HARNESS If removing a wire harness, check the wiring and clamping before proceeding so that it can be restored in the same way. Never twist, pull or slacken the wire harness more than necessary. The wire harness should never come into contact with any high temperature part, rotating, moving, vibrating, or sharp-edged parts. Avoid contact with panel edges, screw tips and other sharp items. When installing parts, never pinch the wire harness. Never cut or break the cover of the wire harness. If it is cut or broken, replace it or repair it with vinyl tape.
2. CHECK FOR OPEN CIRCUIT For an open circuit in the wire harness in (Scheme 46), measure the resistance and voltage as follows: Check the resistance. Disconnect connectors A and C and measure the resistance between the terminals of the connectors. Standard resistance (Scheme 47) TESTER CONNECTION SPECIFIED CONDITION TABLE Tester Connection Specified Condition Connector A terminal 1 - Connector C terminal 1 10 kohms or higher Connector A terminal 2 - Connector C terminal 2 Below 1 ohms HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the preceding values, an open circuit exists between terminal 1 of connector A and terminal 1 of connector C. Disconnect connector B and measure the resistance between the terminals of the connectors. Standard resistance (Scheme 48) TESTER CONNECTION SPECIFIED CONDITION TABLE Tester Connection Specified Condition Connector A terminal 1 - Connector B1 terminal 1 Below 1 ohms Connector B2 terminal 2 - Connector C terminal 2 10 kohms or higher If the results match the values specified above, an open circuit exists between terminal 1 of connector B2 and terminal 1 of connector C. Check the voltage. In a circuit in which voltage is applied to the ECU connector terminal, an open circuit can be checked by conducting a voltage check. With each connector still connected, measure the voltage between the body ground and these terminals (in this order): 1) terminal 1 of connector A, 2) terminal 1 of connector B, and 3) terminal 1 of connector C. Standard voltage (Scheme 49) TESTER CONNECTION SPECIFIED CONDITION TABLE Tester Connection Specified Condition Connector A terminal 1 - Body ground 5 V Connector B terminal 1 - Body ground 5 V Connector C terminal 1 - Body ground Below 1 V If the results match the values specified above, an open circuit exists in the wire harness between terminal 1 of connector B and terminal 1 of connector C.
3. CHECK FOR SHORT CIRCUIT If the wire harness is shorted to ground (Scheme 50), locate the section by conducting the following resistance check with body ground. Check the resistance with body ground. Disconnect connectors A and C and measure the resistance. Standard resistance (Scheme 51) TESTER CONNECTION SPECIFIED CONDITION TABLE Tester Connection Specified Condition Connector A terminal 1 - Body ground Below 1 ohms Connector A terminal 2 - Body ground 10 kohms or higher HINT: Measure the resistance while lightly shaking the wire harness vertically and horizontally. If the results match the values specified above, a short circuit exists between terminal 1 of connector A and terminal 1 of connector C. Disconnect connector B and measure the resistance. Standard resistance (Scheme 52) TESTER CONNECTION SPECIFIED CONDITION TABLE Tester Connection Specified Condition Connector A terminal 1 - Body ground 10 kohms or higher Connector B2 terminal 2 - Body ground Below 1 ohms If the results match the preceding values, a short circuit exists between terminal 1 of connector B2 and terminal 1 of connector C.
4. CHECK AND REPLACE ECU NOTE: The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. When no measuring condition is specified, perform the inspection with the engine stopped and the ignition switch on (IG). Check that the connectors are fully seated. Check for loose, corroded or broken wires. First, check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty. Temporarily replace the ECU with a normally functioning one and check if the symptoms occur. If the trouble symptoms disappear, replace the original ECU. Measure the resistance between the ECU ground terminal and body ground. Standard resistance: Below 1 ohms Disconnect the ECU connector. Check the ground terminal on the ECU side and wire harness side for bending, corrosion or foreign matter. Lastly, check the contact pressure of the female terminals.

Scheme 55

Scheme 56

Scheme 57

1. OPERATION FLOW HINT: Perform troubleshooting in accordance with the procedures below. The following is an outline of basic troubleshooting procedures. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting. VEHICLE BROUGHT TO WORKSHOP CUSTOMER PROBLEM ANALYSIS Ask the customer about the conditions and environment when the problem occurred. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding. SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK Visually check the wire harnesses, connectors and fuses for open and short circuits. Warm up the engine to the normal operating temperature. Confirm the problem symptoms and conditions, and check for DTCs. Result RESULT TABLE Result Proceed to DTC is output A DTC is not output B B: GO TO STEP 6 A: Go to next step DTC TABLE Check the results obtained in step 4 . Then find the output DTC in the DTC table. Look at the "Trouble Area" column for a list of potentially malfunctioning circuits and/or parts. NEXT: GO TO STEP 7 PROBLEM SYMPTOMS TABLE Check the results obtained in step 4 . Then find the problem symptoms in the problem symptoms table. Look at the "Suspected Area" column for a list of potentially malfunctioning circuits and/or parts. CIRCUIT INSPECTION OR PARTS INSPECTION Identify the malfunctioning circuit or part. ADJUST, REPAIR OR REPLACE Adjust, repair or replace the malfunctioning circuit or parts. CONFIRMATION TEST After the adjustment, repairs or replacement, confirm that the malfunction no longer exists. If the malfunction does not reoccur, perform a confirmation test under the same conditions and in the same environment as when the malfunction occurred the first time. NEXT: END
2. CUSTOMER PROBLEM ANALYSIS HINT: In troubleshooting, confirm that the problem symptoms have been accurately identified. Preconceptions should be discarded in order to make an accurate judgment. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time the malfunction occurred. Gather as much information as possible for reference. Past problems that seem unrelated may also help in some cases. The following 5 items are important points in the problem analysis: CUSTOMER PROBLEM ANALYSIS TABLE What Vehicle model, system name When Date, time, occurrence frequency Where Road conditions Under what conditions? Driving conditions, weather conditions How did it happen? Problem symptoms
3. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE HINT: The diagnostic system in this vehicle has various functions. The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous malfunction's DTC can be checked by a technician during troubleshooting. Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU correctly. By using these functions, the problem areas can be narrowed down and troubleshooting can be more effective. Diagnostic functions are incorporated in the following system in this vehicle. DIAGNOSTIC TROUBLE CODE TABLE System SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE DTC Check (Normal Mode) DTC Check (Check Mode) Sensor Check/Test Mode (Input Signal Check) DATA LIST ACTIVE TEST 2GR-FE SFI System o o - o o 2GR-FE Smart Key System o - - o o U151E, U151F Automatic Transaxle System o o - o o Tire Pressure Warning System o - o o - Vehicle Stability Control System o - o o o Steering Lock System o - - o o Power Steering System o - - o - Air Conditioning System (for Automatic Air Conditioning System) o - - o o Air Conditioning System (for Manual Air Conditioning System) o - - o o Airbag System o o - o - Seat Belt Warning System - - - o o Theft Deterrent System (w/ Smart Key System) o - - o o Theft Deterrent System (w/o Smart Key System) o - - o o Engine Immobilizer System (w/ Smart Key System) o - - o o Engine Immobilizer System (w/o Smart Key System) o - - o o Cruise Control System o - - o - Lighting System o - - o o Power Door Lock Control System - - - o o Wireless Door Lock Control System (w/ Smart Key System) o - - o o Wireless Door Lock Control System (w/o Smart Key System) o - - o o Smart Key System (DOOR LOCK) - - - o o Key Reminder Warning System - - - o - Meter/Gauge System o - - o o Audio and Visual System o - - - - Navigation System o - - - - Power Window Control System o - - o o Window Defogger System - - - - o Sliding Roof System o - - o o Back Door Closer System o - - o o Power Back Door System o - - o o LIN Communication System o - - o - CAN Communication System o - - - - In the DTC check, it is very important to determine whether the problem indicated by the DTC either: 1) still occurs, or 2) occurred in the past but has returned to normal. In addition, the DTC should be compared to the problem symptom to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine current system conditions, as shown in the diagram below. Never skip the DTC check. Failing to check DTCs may, depending on the case, result in unnecessary troubleshooting for systems operating normally or lead to repairs not related to the problem. Follow the procedures listed in the diagram in the correct order. The following procedures shows how to proceed with troubleshooting using the DTC check. Directions from the procedures will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of each problem symptom. DTC CHECK MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR MEMORY SYMPTOM CONFIRMATION Result RESULT TABLE Result Proceed to No symptoms exist A Symptoms exist B B: GO TO STEP 5 A: Go to next step SIMULATION TEST USING SYMPTOM SIMULATION METHODS DTC CHECK Result RESULT TABLE Result Proceed to DTC is not output A DTC is output B B: TROUBLESHOOTING OF PROBLEM INDICATED BY DTC A: Go to next step SYMPTOM CONFIRMATION Result RESULT TABLE Result Proceed to No symptoms exist A Symptoms exist B If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past. Check the wire harness and connectors. B: SYSTEM NORMAL A: TROUBLESHOOTING OF EACH PROBLEM SYMPTOM The problem still occurs in a place other than the diagnostic circuit (the DTC displayed first is either for a past problem or a secondary problem).
4. SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no problem symptoms occur. In such a case, a thorough problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the problem occurred in the customer's vehicle should be carried out. No matter how much skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked and mistakes or delays. For example: With a problem that only occurs when the engine is cold or as a result of vibration caused by the road during driving, the problem can never be determined if the symptoms are being checked on a stationary vehicle or a vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) are difficult to reproduce. The symptom simulation tests below are effective substitutes for the conditions and can be applied to a stationary vehicle. Important points in the symptom simulation test: In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes. VIBRATION METHOD: When a malfunction seems to occur as a result of vibration. PART AND SENSOR Apply slight vibration with a finger to the part of the sensor suspected to be the cause of the problem, and check whether the malfunction occurs. NOTE: Applying strong vibration to relays may open the relays. CONNECTORS Slightly shake the connector vertically and horizontally. WIRE HARNESS Slightly shake the wire harness vertically and horizontally. HINT: The connector joint and fulcrum of the vibration are the major areas that should be checked thoroughly. HEAT METHOD: When a malfunction seems to occur when the area in question is heated. Heat the component that is the possible cause of the malfunction with a hair dryer or similar device. Check if the malfunction occurs. NOTE: Do not heat to more than 60°C (140°F). Exceeding this temperature may damage the components. Do not apply heat directly to the parts in the ECU. WATER SPRINKLING METHOD: When a malfunction seems to occur on a rainy day or in high-humidity. Sprinkle water onto the vehicle and check if the malfunction occurs. NOTE: Never sprinkle water directly into the engine compartment. Indirectly change the temperature and humidity by spraying water onto the front of the radiator. Never apply water directly onto the electronic components. HINT: If the vehicle has or had a water leakage problem, the leakage may have damaged the ECU or connections. Look for evidence of corrosion or short circuits. Proceed with caution during water tests. HIGH ELECTRICAL LOAD METHOD: When a malfunction seems to occur when an electrical load is excessive. Turn on the heater blower, headlight, rear window defogger and all other electrical loads. Check if the malfunction reoccurs.
5. DIAGNOSTIC TROUBLE CODE TABLE Look for output Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the appropriate section's Diagnostic Trouble Code Table. Use the table to determine the trouble area and the proper inspection procedure. A description of each of the table columns is shown in the table below. DIAGNOSTIC TROUBLE CODE TABLE Item Description DTC No. Indicates the diagnostic trouble code Detection Item Indicates the system or details of the problem Trouble Area Indicates the suspected areas of the problem
6. PROBLEM SYMPTOMS TABLE When a "Normal" code is output during a DTC check but the problem still occurs, use the Problem Symptoms Table. The suspected areas (circuits or parts) for each problem symptoms are shown in the table. The suspected areas are listed in order of probability. A description of each of the table columns is shown in the following table. HINT: In some cases, the problem is not detected by the diagnostic system even though a problem symptom occurs. It is possible that the problem occurs outside the detection range of the diagnostic system, or that the problem occurs in a completely different system. PROBLEM SYMPTOMS TABLE Item Description Problem Symptom - Circuit Inspection, Inspection Order Indicates the order in which the circuits need to be checked Circuit or Part Name Indicates the circuit or part which needs to be checked
7. CIRCUIT INSPECTION A description of the main areas of each circuit inspection is shown in the following table. CIRCUIT INSPECTION Item Description Circuit Description The major role, operation of the circuit and its component parts are explained. Diagnostic Trouble Code No. and Detection Item Indicates the diagnostic trouble codes, diagnostic trouble code settings and suspected areas for a problem. Wiring Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL WIRING DIAGRAM to thoroughly understand the circuit. Wire colors are indicated by an alphabetical code. B = Black, L = Blue, R = Red, BR = Brown, LG = Light Green, V = Violet, G = Green, O = Orange, W = White, GR = Gray, P = Pink, Y = Yellow, SB = Sky Blue The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Inspection Procedures Use the inspection procedures to determine if the circuit is normal or abnormal. If abnormal, use the inspection procedures to determine whether the problem is located in the sensors, actuators, wire harnesses or ECU. Graphic of the ECU connector during the check Connector being checked is connected. Connections of a tester are indicated by (+) or (-) after the terminal name. Connector being checked is disconnected. Inspections between a connector and body ground. Information about body ground is not shown in the graphic.

ABBREVIATIONS

ABBREVIATIONS TABLE

See also:
• PREPARATION
• DISPOSAL
• INSTALLATION
• ROAD TEST
• REGISTRATION