Engine TOYOTA HIGHLANDER HYBRID 2006 XU40 / 2.G Service Manual

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CAUTION
Avoid inhaling the engine exhaust.
It contains carbon monoxide, which
is a colorless and odorless gas. It
can cause unconsciousness or even
death.
Make sure the exhaust system has
no holes or loose connections. The
system should be checked from
time to time. If you hit something,
or notice a change in the sound of
the exhaust, have the system
checked immediately.
Do not run the hybrid system in a
garage or other enclosed areas ex-
cept to drive the vehicle in or out.
In enclosed areas, exhaust gases
cannot escape, making this a partic-
ularly dangerous situation.
Do not remain for a long time in a
parked vehicle with the hybrid sys-
tem on. If it is unavoidable, howev-
er, make sure to park the vehicle in
an unclosed area and adjust the
heating or cooling system to force
outside air into the vehicle.
Keep the back door closed while
driving. An open or unsealed back
door may cause exhaust gases to
be drawn into the vehicle.
To allow proper operation of your
vehicle’s ventilation system, keep
the inlet grilles in front of the wind-
shield clear of snow, leaves, or oth-
er obstructions.
If you smell exhaust fumes in the
vehicle, drive with the windows
open and the back door closed.
Have the cause immediately located
and corrected.
FUNCTIONS OF ENGINE OIL
Engine oil has the primary functions of
lubricating and cooling the inside of the
engine, and plays a major role in main-
taining the engine in proper working order.
ENGINE OIL CONSUMPTION
It is normal that an engine should con-
sume some engine oil during normal
engine operation. The causes of oil
consumption in a normal engine are as
follows.
Oil is used to lubricate pistons, piston
rings and cylinders. A thin film of oil
is left on the cylinder wall when a pis-
ton moves downwards in the cylinder.
High negative pressure generated when
the vehicle is decelerating sucks some
of this oil into the combustion chamber.
This oil as well as some part of the oil
film left on the cylinder wall is burned
by the high temperature combustion
gases during the combustion process.
Oil is also used to lubricate the stems
of the intake valves. Some of this oil
is sucked into the combustion chamber
together with the intake air and is
burned along with the fuel. High tem-
perature exhaust gases also burn the
oil used to lubricate the exhaust valve
stems.
Engine exhaust cautions Facts about engine oil
consumption

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The amount of engine oil consumed de-
pends on the viscosity of the oil, the
quality of the oil and the conditions the
vehicle is driven under.
More oil is consumed by high−speed driv-
ing and frequent acceleration and decel-
eration.
A new engine consumes more oil, since
its pistons, piston rings and cylinder walls
have not become conditioned.
Oil consumption: Max. 1.0 L per 1000
km (1.1 qt./600 miles, 0.9 Imp. qt./600
miles)
When judging the amount of oil con-
sumption, note that the oil may become
diluted and make it difficult to judge
the true level accurately.
As an example, if a vehicle is used for
repeated short trips, and consumes a nor-
mal amount of oil, the dipstick may not
show any drop in the oil level at all, even
after 1000 km (600 miles) or more. This
is because the oil is gradually becoming
diluted with fuel or moisture, making it
appear that the oil level has not changed.
The diluting ingredients evaporate out
when the vehicle is then driven at high
speeds, as on an expressway, making it
appear that oil is excessively consumed
after driving at high speeds. IMPORTANCE OF ENGINE OIL LEVEL
CHECK
One of the most important points in prop-
er vehicle maintenance is to keep the en-
gine oil at the optimum level so that oil
function will not be impaired. Therefore, it
is essential that the oil level be checked
regularly. Toyota recommends that the oil
level be checked every time you refuel
the vehicle.
NOTICE
Failure to check the oil level regularly
could lead to serious engine trouble
due to insufficient oil.
For detailed information on oil level check,
see “Checking the engine oil level” on
page 386 in Section 7
−2.
Your engine is fitted with iridiumtipped
spark plugs.
NOTICE
Use only iridiumtipped spark plugs
and do not adjust gaps for your en-
gine performance and smooth drive-
ability.
Iridiumtipped spark plugs

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REGENERATIVE BRAKE
When the brake is applied, the motor gen-
erator converts kinetic energy into electric
energy.
The regenerative brake works in the fol-
lowing operations.
1. When the accelerator pedal is released, the reduced speed equal to engine
braking in a gasoline −fueled vehicle is
obtained in accordance with the running
mode position of the selector lever.
2. When the brake pedal is depressed with the selector lever in “D” or “B”,
the regenerative brake works.
HYDRAULIC BRAKE
This brake system has 3 independent hy-
draulic circuits. If any circuit should fail,
the other will still work. However, the ped-
al will be harder to press, and your stop-
ping distance will increase. Also, the
brake system warning light may come on.
CAUTION
Do not drive your vehicle with only a
single brake system. Have your
brakes fixed immediately.
BRAKE ACTUATOR
The brake actuator uses brake fluid pres-
surized by the pump to power −assist the
brakes. If the brake actuator fails during
driving, the brake system warning light
comes on and the buzzer sounds continu-
ously. In this case, the brakes may not
work properly. If they do not work well,
depress the brake pedal firmly. If the
brake system warning light comes on, im-
mediately stop your vehicle and contact
your Toyota dealer.
The red and yellow brake system warning
lights may stay on for about 60 seconds
after the ignition is turned on. It is normal
if the light turns off after a while.
Depressing the brake pedal repeatedly
may turn on the red warning light. It is
normal if the light turns off after a few
seconds.
You may hear a sound in the engine
compartment after the hybrid system is
started or the brake pedal is depressed
repeatedly. This is a pump pulsating
sound of the brake system, and it is not
a malfunction. In the following conditions, you may hear
a motor sound in the engine compartment.
The brake pedal is depressed when the
hybrid system is turned off.
The driver ’s door is opened.
For a few seconds after the hybrid sys-
tem is off and about 90 seconds have
passed.
The brake pedal stroke may be short
when you turn the ignition on with the
brake pedal depressed.
CAUTION
Do not pump the brake pedal if the
hybrid system is not operating.
Each push on the pedal uses up
your reserved brake fluid pressure.
Even if the power assist is com-
pletely lost, the brakes will still
work. But you will have to push the
pedal hard, much harder than nor-
mal. And your braking distance will
increase.
Brake system

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The vehicle identification number (VIN)
is the legal identifier for your vehicle.
This number is on the left top of the
instrument panel, and can be seen
through the windshield from outside.
This is the primary identification number
for your Toyota. It is used in registering
the ownership of your vehicle.The vehicle identification number (VIN) is
also on the Certification Label.1. Gasoline engine number
2. Traction motor number
The gasoline engine and traction motor
numbers are stamped as shown.
Your Toyota’s identification—
—Vehicle identification
number —Gasoline engine and
traction motor numbers

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Ti r e relat ed ter mMeaning
Accessory weight
the combined weight (in excess of those standard items which may be
replaced) of transaxle, power steering, power brakes, power windows,
power seats, radio, and heater, to the extent that these items are available
as factory−installed equipment (whether installed or not)
Cold tire inflation pressure
tire inflation pressure when the vehicle has been parked for at least 3
hours or more, or it has not been driven more than 1.5 km or 1 mile
under that condition
Curb weight
the weight of a motor vehicle wi th standard equipment including the
maximum capacity of fuel, oil, and coolant, and, if so equipped, air
conditioning and additional weight optional engine
Intended outboard sidewall
(A) the sidewall that contains a whitewall, bears white lettering or bears manufacturer, brand, and/or model name molding that is higher or
deeper than the same molding on th e other sidewall of the tire, or
(B) the outward facing sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a vehicle
Maximum inflation pressurethe maximum cold inflation pressure to which a tire may be inflated and it
is shown on the sidewall of the tire
Maximum loaded vehicle weight
t he sum of —
(a) curb weight;
(b) accessory weight;
(c) vehicle capacity weight; and
(d) production options weight
—Glossary of tire terminology

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1. Check the area around the vehicle be-
fore getting in.
2. Adjust seat position, seatback angle, seat cushion angle, seat height, head
restraint height and steering wheel
angle.
3. Adjust the inside and outside rear view mirrors.
4. Lock all side doors and back door.
5. Fasten seat belts.
When you get in the vehicle, check
whether the “READY” light is on or
not.
CAUTION
Your vehicle does not produce any
noise or vibration when the vehicle is
ready to be driven with the “READY”
indicator light on. Move your foot
carefully from the brake pedal to the
acceleration pedal when driving.
1. Apply the parking brake firmly.
2. Turn off unnecessary lights and acces- sories.
3. Put the selector lever in “P”.
4. Depress the brake pedal and hold it to the floor until driving off.
As the hybrid system starts only with the
transmission in the “P” position, put the
selector lever in “P” whenever starting the
system.
Before starting the hybrid system, be sure
to follow the instructions in “(a) Before
starting”.
Starting procedure
With your foot off the accelerator pedal,
turn the key to “START” briefly and firmly.
After a few seconds, the “READY” light
will come on and a beep will sound. If the
ambient temperature is low, such as dur-
ing winter driving conditions, it may take
time until the “READY” light comes on.
The engine may not start even with the
“READY” light on.
Before starting the hybrid
system How to start the hybrid
system—
(a) Before starting (b) Starting the hybrid system

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You may hear a sound in the engine
compartment when the brake pedal is de-
pressed with the hybrid system off. How-
ever, this does not indicate any trouble.
When the hybrid system is started or
stopped, you may hear a sound coming
from the traction battery under the rear
seats. However, this does not indicate any
trouble.
When the hybrid system is started or
stopped, or while the vehicle is idling, you
may hear a sound coming from the trans-
mission. However, this does not indicate
any trouble.
When applying brakes, you may hear a
sound coming from the regenerative
brakes. However, this does not indicate
any trouble.
When the gasoline engine is started or
stopped with the hybrid system on, you
may feel a vibration. However, this does
not indicate any trouble.
If there is a problem somewhere in the
hybrid system, “CHECK HYBRID SYSTEM”
warning message will appear on the multi −
information display. Have your vehicle
checked by your Toyota dealer as soon as
possible. If the hybrid system will not start...
See “If your vehicle will not start” on page
340 in Section 4.
CAUTION
Never start the hybrid system from
outside the vehicle, or an accident
may occur. Be sure to sit in the driv-
er seat, then start the system.
NOTICE

If any service reminder indicator
light comes on or warning message
appears on the multiinformation
display (see page 144 and page 155
for details) or the auxiliary battery
is disconnected, the hybrid system
may not start. In that case, turn the
ignition on again. If the “READY”
light does not come on, contact
your Toyota dealer.
 When you start the hybrid system
at a lower outside temperature, it
may take longer before the blinking
“READY” light changes to constant
on.
Always slow down in gusty crosswinds.
This will allow you much better control.
Drive slowly onto curbs and, if pos-
sible, at a right angle. Avoid driving
onto high, sharp− edged objects and
other road hazards. Failure to do so
can lead to severe tire damage such
as a tire burst.
Drive slowly when passing over bumps
or travelling on a bumpy road. Other-
wise, the impact could cause severe
damage to the tires and/or wheels.
When parking on a hill, turn the front
wheels until they touch the curb so
that the vehicle will not roll. Apply the
parking brake, and place the transmis-
sion in “P”. If necessary, block the
wheels.
Washing your vehicle or driving through
deep water may get the brakes wet. To
see whether they are wet, check that
there is no traffic near you, and then
press the pedal lightly. If you do not
feel a normal braking force, the brakes
are probably wet. To dry them, drive
the vehicle cautiously while lightly
pressing the brake pedal with the park-
ing brake applied. If they still do not
work safely, pull to the side of the road
and call a Toyota dealer for assistance.
Tips for driving in various
conditions

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Take all necessary safety measures
to ensure that water damage to the
traction battery, hybrid system or
other components does not occur.
Water entering the engine compart-
ment may cause severe damage to
the hybrid system. Water entering
the interior may cause the traction
battery stowed under the rear seats
to short circuit.
Water can wash the grease from
wheel bearings, causing rusting and
premature failure, and may also en-
ter the transaxle case, reducing the
gear oil’s lubricating qualities.
 Sand and mud that has accumulated
in brake drums and around brake
discs may affect braking efficiency
and may damage brake system com-
ponents.
 Always perform a maintenance in-
spection after each day of offroad
driving that has taken you through
rough terrain, sand, mud, or water.
For scheduled maintenance informa-
tion, refer to the “Scheduled Main-
tenance Guide” or “Owner’s Manual
Supplement”.Make sure your coolant is properly pro-
tected against freezing.
Only use “Toyota Super Long Life Coolant”
or similar high quality ethylene glycol
based non −silicate, non −amine, non −nitrite,
and non− borate coolant with long −life
hybrid organic acid technology. (Coolant
with long −life hybrid organic acid
technology is a combination of low
phosphates and organic acids.)
See “Checking the coolant level” on page
388 in Section 7 −2 for details of coolant
type selection.
For the U.S.A.—“Toyota Super Long Life
Coolant” is a mixture of 50% coolant and
50% deionized water. This coolant pro-
vides protection down to about −35 C
( − 31 F).
For Canada—“Toyota Super Long Life
Coolant” is a mixture of 55% coolant and
45% deionized water. This coolant pro-
vides protection down to about −42 C
( − 44 F).
NOTICE
Do not use plain water alone.
Check the status of the traction battery.
See page 4 for the status of the traction
battery. If the traction battery is dis-
charged, the hybrid system will not start
up.
Check the condition of the auxiliary
battery and cables.
Cold temperatures lower the performance
of the auxiliary battery, so it must be in
top shape to provide enough power for
winter starting. Section 7 −3 tells you how
to visually inspect the auxiliary battery.
Your Toyota dealer and most service sta-
tions will be pleased to check the charge
level.
Make sure the engine oil viscosity is
suitable for the cold weather.
See page 386 in Section 7 −2 for recom-
mended viscosity. Leaving a heavy sum-
mer oil in your vehicle during winter
months may cause harder starting. If you
are not sure about which oil to use, call
your Toyota dealer—they will be pleased
to help.
Keep the door locks from freezing.
Squirt lock de −icer or glycerine into the
locks to keep them from freezing.
Winter driving tips

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Use a washer fluid containing an anti-
freeze solution.
This product is available at your Toyota
dealer and most auto parts stores. Follow
the manufacturer ’s directions for how
much to mix with water.
NOTICE
Do not use engine antifreeze or any
other substitute because it may dam-
age your vehicle’s paint.
Do not use your parking brake when
there is a possibility it could freeze.
When parking, put the transmission into
“P” and block the rear wheels. Do not use
the parking brake, or snow or water accu-
mulated in and around the parking brake
mechanism may freeze, making it hard to
release.
Keep ice and snow from accumulating
under the fenders.
Ice and snow built up under your fenders
can make steering difficult. During bad
winter driving, stop and check under the
fenders occasionally. Depending on where you are driving,
we recommend you carry some emer-
gency equipment.
Some of the things you might put in the
vehicle are tire chains, window scraper,
bag of sand or salt, flares, small shovel,
jumper cables, etc.Your vehicle is not designed to be
dinghy towed (with four wheels on the
ground) behind a motorhome.
NOTICE
Do not tow your vehicle with four
wheels on the ground. This may
cause serious damage to your vehicle.
Dinghy towing

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BREAKIN SCHEDULE
Toyota recommends that you do not
tow a trailer with a new vehicle or a
vehicle with any new power train com-
ponent (engine, traction motor, trans-
mission, wheel bearings, etc.) for the
first 800 km (500 miles) of driving.
MAINTENANCE
If you tow a trailer, your vehicle will
require more frequent maintenance due
to the additional load. For this informa-
tion, please refer to the scheduled
maintenance information in the “Sched-
uled Maintenance Guide” or “Owner ’s
Manual Supplement”.
Retighten all fixing bolts of the towing
ball and bracket after approximately
1000 km (600 miles) of trailer driving. PRETOWING SAFETY CHECK
Check that your vehicle remains level
when a loaded or unloaded trailer is
hitched. Do not drive if the vehicle has
an abnormal nose
−up or nose −down
condition, and check for improper
tongue load, overload, worn suspension
or other possible causes.
Make sure the trailer cargo is securely
loaded so that it cannot shift.
Check that your rear view mirrors con-
form to any applicable federal, state/
provincial or local regulations. If not,
install the rear view mirrors required
for towing purposes.
TRAILER TOWING TIPS
When towing a trailer, your vehicle will
handle differently than when not tow-
ing. The three main causes of vehicle
trailer accidents are driver error, exces-
sive speed and improper trailer loading.
Keep these in mind when towing:
Before starting out, check operation of
the lights and all vehicle −trailer connec-
tions. After driving a short distance,
stop and recheck the lights and con-
nections. Before actually towing a trail-
er, practice turning, stopping and back-
ing with a trailer in an area away from
traffic until you learn the feel.
Backing with a trailer is difficult and
requires practice. Grip the bottom of
the steering wheel and move your hand
to the left to move the trailer to the
left. Move your hand to the right to
move the trailer to the right. (This pro-
cedure is generally opposite to that
when backing without a trailer.) Also,
just turn the steering wheel a little at
a time, avoiding sharp or prolonged
turning. Have someone guide you when
backing to reduce the risk of an acci-
dent.
Because stopping distance may be in-
creased, vehicle− to−vehicle distance
should be increased when towing a
trailer. For each 16 km/h (10 mph) of
speed, allow at least one vehicle and
trailer length between you and the ve-
hicle ahead. Avoid sudden braking as
you may skid, resulting in jackknifing
and loss of control. This is especially
true on wet or slippery surfaces.
Avoid jerky starts or sudden accelera-
tion.
Avoid jerky steering and sharp turns.
The trailer could hit your vehicle in a
tight turn. Slow down before making a
turn to avoid the necessity of sudden
braking.