TOYOTA HIGHLANDER 2001 Service Repair Manual

D30401
Mark
D25096
Example:
CORRECT INCORRECT
Z13950
Example:
NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER
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01-1 1
11 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(b) SPIRAL CABLE (in Combination Switch)
(1) The steering wheel must be fitted correctly to the
steering column with the spiral cable at the neutral
position, otherwise cable disconnection and other
problems may occur. Refer to page 60-26 for in-
formation about correct installation of the steering
wheel.
(c) HORN BUTTON ASSEMBLY (with Airbag)
(1) When removing the horn button assembly or handling a new horn button, it should be placed with
the pad surface facing up. See illustration below.
Placing the horn button with the pad surface facing down may lead to a serious accident if the
airbag accidently inflates. Also, do not place anything on top of the horn button.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which
could cause serious injury.
(3) Grease or detergents of any kind should not be applied to the steering wheel pad.
(4) Store the horn button assembly in an area where the ambient temperature is below 93°C
(200°F), the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors
(4 pins). These connectors contain shorting springs. This feature reduces the possibility of the
airbag or seat belt pretensioner deploying due to currents entering the squib wiring.
(6) When disposing of the vehicle or the horn button assembly by itself, the airbag should be inflated
using an SST before disposal (see page 60-19). Perform the operation in a safe place away from
electrical noise.

D27522
Example:
CORRECT INCORRECT
Z13951
Example:
NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER 01-12
- INTRODUCTIONREPAIR INSTRUCTION
12 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(d) INSTRUMENT PANEL PASSENGER AIRBAG ASSY
(1) Always place a removed or new instrument panel passenger airbag assembly with the airbag
inflation direction facing up.
Placing the airbag assembly with the airbag inflation direction facing down could cause a serious
accident if the airbag inflates.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which
could cause serious injury.
(3) Grease or detergents of any kinds should not be applied to the instrument panel passenger air-
bag assembly.
(4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F),
the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors
(4 pins). These connectors contain shorting springs. This feature reduces the possibility of the
airbag deploying due to currents entering the squib wiring.
(6) When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed
using SST before disposal (see page 60-31).
Activate in a safe place away from electrical noise.
(e) CURTAIN SHIELD AIRBAG ASSEMBLY
(1) Always place the removed or new curtain shield airbag assembly in a clear plastic bag, and keep
it in a safe place.
NOTICE:
Plastic bag is not re-useable.
CAUTION:
Never disassemble the curtain shield airbag assembly.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which
is very dangerous.
(3) Grease should not be attached to the curtain shield airbag assembly, and the surface should not
be cleared with detergents of any kind.

D31641
Example:
CORRECT
Clear Plastic Bag
INCORRECT
D30931NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER
- INTRODUCTIONREPAIR INSTRUCTION
01-13
13 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F),
the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors
(2 pins). These connectors contain shorting springs. This feature reduces the possibility of the
airbag deploying due to currents entering the squib wiring.
(6) When disposing of a vehicle or the curtain shield airbag assembly unit, the airbag should be
deployed using SST before disposal (see page 60-40).
Activate in a safe place away from electrical noise.
(f) FRONT SEAT AIRBAG ASSEMBLY
(1) Always place a removed or new front seat airbag assembly with the airbag inflation direction fac-
ing up. Placing the airbag assembly with the airbag inflation direction facing downward could
cause a serious accident if the airbag deploys.
(2) Never measure the resistance of the airbag squib. This may cause the airbag to inflate, which
is very dangerous.
(3) Grease should not be applied to the front seat airbag assembly, and the airbag door should not
be cleaned with detergents of any kind.
(4) Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F),
the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors
(2 pins). These connectors contain shorting springs. This feature reduces the possibility of the
airbag deploying due to currents entering the squib wiring.
(6) When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed
using SST before disposal (see page 60-46).
Activate in a safe place away from electrical noise.

D30924
Example:
NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER
D30370
Example:
NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER 01-14
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(g) SEAT BELT PRETENSIONER
(1) Never measure the resistance of the seat belt pretensioner. This may cause the seat belt preten-
sioner to activate, which is very dangerous.
(2) Never disassemble the seat belt pretensioner.
(3) Never install the seat belt pretensioner on another vehicle.
(4) Store the seat belt pretensioner in area where the ambient temperature is below 80°C (176°F),
the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors
(2 pins). These connectors contain shorting springs. This feature reduces the possibility of the
airbag deploying due to currents entering the squib wiring.
(6) When disposing of a vehicle or the seat belt pretensioner unit by itself, the seat belt pretensioner
should be activated before disposal (see page 61-8). Activate in a safe place away from electri-
cal noise.
(7) The seat belt pretensioner is hot after being activated, so allow some time for it to cool down suffi-
ciently before disposal. Never apply water to cool down the seat belt pretensioner.
(8) Oil or water should not be put on the front seat outer belt, and the front seat outer belt should
not be cleaned with detergents of any kind.
(h) AIRBAG SENSOR ASSEMBLY
(1) Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has
deployed.
(2) 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 accidental deployment of the SRS.
(3) Work must be started at least 90 seconds after 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.

D25080
Negative (-)
Terminal
D31751
INCORRECT
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(i) WIRE HARNESS AND CONNECTOR
(1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All the con-
nectors in the system are a standard yellow color. If the SRS wire harness becomes discon-
nected or the connector becomes broken, repair or replace it.
2. ELECTRONIC CONTROL
(a) REMOVAL AND INSTALLATION OF BATTERY TERMI-
NAL
(1) Before performing electronic work, disconnect the
battery negative (-) terminal cable beforehand to
prevent component and wire damage caused by
accidental short circuits.
(2) When disconnecting and installing the terminal
cable, turn the ignition switch and lighting switch
OFF and loosen the terminal nut completely. Per-
form these operations without twisting or prying the
terminal. Remove the battery cable from battery
post.
(3) Clock settings, radio settings, DTCs and other data
are erased when the battery cable is removed. Be-
fore removing the battery cable, record any neces-
sary data.
(4) When disconnecting the battery's negative (-) ter-
minal cable, re-initialize the following systems after
the completion of the operation.
(b) HANDLING OF ELECTRONIC PARTS
(1) 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.
(2) To disconnect electronic connectors, pull the con-
nector itself, not the wires.
(3) Be careful not to drop electronic components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced.
(4) When cleaning the engine with steam, protect the
electronic components, air filter and emission-re-
lated components from water.
(5) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(6) When checking the continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.

D01563
D25081
Spring Type Clamp
Clamp Track
D20025
01-16
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
3. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Work in a place with good air ventilation and without any ignition sources, such as a welder, grind-
er, drill, electric motor or stove.
(2) Never work in a place such as a pit or near a pit because vaporized fuel will collect in those places.
(b) REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Prepare a fire extinguisher before starting operation.
(2) To prevent static electricity, install a ground on the fuel changer, vehicle and fuel tank, and do
not spray the area with water. The work surface will become slippery. Do not clean up spills with
water as this will spread and gasoline and create a fire hazard.
(3) Never use any electric equipment like an electric motor or a working light, as they may create
sparks or high temperatures.
(4) Never use an iron hammer, as it may create sparks.
(5) Dispose of fuel-contaminated shop rags separately using a fire resistant container.
4. REMOVAL AND INSTALLATION OF ENGINE INTAKE
PARTS
(a) If any metal particle enters the inlet pass, this may dam-
age the engine.
(b) When removing and installing the inlet system parts, cov-
er the openings of the removed parts and engine open-
ings. Use clean shop rags, gummed tape, or other suit-
able materials.
(c) When installing the inlet system parts, check that no metal
particles have entered the engine or the installed part.
5. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the clamp position so
that you can restore it in the same way.
(b) Replace deformed or dented clamps with new ones.
(c) When reusing a hose, attach the clamp on the clamp track
portion of the hose.
(d) For a spring type clamp, to spread the tabs slightly after
installation by pushing in the direction of the arrow marks
as shown in the illustration.
6. FOR VEHICLES EQUIPPED WITH MOBILE COMMU-
NICATION SYSTEMS
(a) Install the antenna as far away from the ECU and sensors
of the vehicle electronic systems as possible.
(b) Install an antenna feeder at least 20 cm (7.87 in.) away
from the ECU and sensors of the vehicle electronic sys-
tems. For details of the ECU and sensors locations, refer
to the section on applicable components.
(c) Keep the antenna and feeder separate from other wirings
as much as possible. This will prevent signals from the
communication equipment from affecting vehicle equip-
ment and vice-versa.
(d) Check that the antenna and feeder are correctly adjusted.
(e) Do not install any high-powered mobile communication
system.

A82779
DLC3
1314 1516 12 11 10 9 12345678
TS
CG
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
7. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRAC) SYSTEM
(a) When testing with a 2-wheel drum tester such as a speedometer tester, a combination tester of the
speedometer and brake, a chassis dynamometer, or when jacking up the front wheels and driving the
wheels, always turn the TRAC system OFF beforehand via the TRAC OFF switch before testing.
NOTICE:
TRAC system OFF condition can be confirmed by the ºTRAC OFFº warning indicator light in the com-
bination meter.
8. FOR VEHICLES EQUIPPED WITH VEHICLE SKID
CONTROL (VSC) SYSTEM
(a) NOTICES WHEN USING DRUM TESTER
(1) Before beginning testing, disable the Vehicle Skid
Control system (VSC). To disable the VSC, turn the
ignition switch OFF and connect SST to terminals
TS and CG of DLC3.
SST 09843-18040
NOTICE:

Confirm that the VSC warning light blinks.

VSC system will be reset when the engine is re-
started.

For safety, secure the vehicle with restraint chains
while using a wheel dynamometer.
(b) NOTICES OF RELATED OPERATIONS TO VSC
(1) Do not carry out unnecessary installation and re-
moval as it might affect the adjustment of VSC re-
lated parts.
(2) Be sure to follow the instructions for work prepara-
tion and final confirmation of proper operation of the
VSC system.

D25530
D25531
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
9. WHEN SERVICING FULL-TIME 4WD VEHICLES
(a) MEASURING POINTS FOR SPEEDOMETER TESTER
NOTICE:

Tester with a function of load setting 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 (when using free roller, it must be below 50
km/h).

Driving time should be within 1 minute.
(1) Place the front wheels onto the rollers.
(2) Set the rear wheels free by free rollers or rigid racks.
(3) Fasten the vehicle with the lock chain.
(4) Start the engine, and then measure the vehicle
speed by increasing the speed gradually in the D
range.
(5) After the measurement completion, decrease the
vehicle speed by brake gradually, and then stop the
vehicle.
(b) MEASURING POINTS FOR BRAKE TESTER
NOTICE:

Tester with a function of load measurement cannot be used

High-speed type brake cannot be used.
(1) Place the wheels to be measured (front or rear) onto the rollers.
(2) Shift the shift lever into neutral.
(3) Perform the measurement by driving the tester rollers.
HINT:
In case that the dragging force is over 10% of the load put on the axis, inspection of the wheel's rotating
condition should be done with both of the left and right axes jacked up. If no abnormality is found in the rotat-
ing condition, adhesive torque of the viscous coupling causes the excessive dragging fore and therefore it
means no problem exists in the vehicle.

D25532
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) MEASURING POINTS FOR ON-VEHICLE BALANCER
(1) Jack up all 4 wheels with 2 post lifts.
(2) 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.
(3) Support the vehicle with rigid racks so that vehicle
will not lean in the vehicle's front/rear direction.
(4) Release the parking brake.
(5) Check that no dragging force exists by turning each
wheel by hand.
(6) Set the wheel balancers.
(7) Measurement should be done by using both of en-
gine drive and wheel balancer roller drive.
NOTICE:

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 brake gradually.

Take special care that the vehicle does not move.

Measurement should be done quickly.
10. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER
CAUTION:
If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause ove-
heating and create a fire hazard. To prevent this, observe the following precautions.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid idling the engine for more than 20 minutes.
(c) Avoid a spark jump test.
(1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as pos-
sible.
(2) While testing, never race the engine.
(d) Avoid a prolonged engine compression measurement.
Engine compression measurements must be performed as rapidly as possible.
(e) 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.

D25534
INCORRECT
D25533
INCORRECT
D25529
Flat Bed Truck
Wheel Lift Type Truck 01-20
- INTRODUCTIONREPAIR INSTRUCTION
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
11. WHEN TOWING FULL-TIME 4WD VEHICLES
(a) 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.
(b) Never tow the vehicle with either condition of the front
wheels only or the rear only held up.
NOTICE:
Towing with either condition of the front wheels only the
rear wheels only held up might cause the drive train
burned-out or the wheels flying off the dolly.
(c) Towing the vehicle should be done by one of the towing
methods as shown in the illustration.
(d) If the vehicle has a trouble in the chassis or drive train, use
the wheel lift type truck.
Towing MethodParking BrakeTransaxle Shift
Lever Position
Flat Bed TruckAppliedAny Position
Wheel Lift Type TruckAppliedAny Position
NOTICE:
Do not use any towing method other those shown above.