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

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2006 HIGHLANDER (Hybrid) from Mar. ’05 Prod. (OM48530U)
Tire inflation pressure
Check the pressure with a gauge ev-
ery two weeks, or at least once a
month. See page 391 in Section 7 −2
for additional information.
Tire surface and wheel nuts
Check the tires carefully for cuts,
damage or excessive wear. See page
393 in Section 7− 2 for additional in-
formation. When checking the tires,
make sure no nuts are missing, and
check the nuts for looseness. Tighten
them if necessary.
Tire rotation
Rotate the tires according to the
maintenance schedule. (For sched-
uled maintenance information, please
refer to the “Scheduled Maintenance
Guide” or “Owner ’s Manual Supple-
ment”.) See page 395 in Section 7 −2
for additional information.Be on the alert for changes in perfor-
mance, sounds, and visual tip −offs that
indicate service is needed. Some impor-
tant clues are as follows:
Engine missing, stumbling, or pinging
Appreciable loss of power
Strange engine noises
A leak under the vehicle (however, wa-
ter dripping from the air conditioning
after use is normal.)
Change in exhaust sound (This may
indicate a dangerous carbon monoxide
leak. Drive with the windows open and
have the exhaust system checked im-
mediately.)
Flat −looking tire; excessive tire squeal
when cornering; uneven tire wear
Vehicle pulls to one side when driving
straight on a level road
Strange noises related to suspension
movement
Loss of brake effectiveness; spongy
feeling brake pedal; pedal almost
touches floor; vehicle pulls to one side
when braking
Engine coolant temperature continually
higher than normal If you notice any of these clues, take your
vehicle to your Toyota dealer as soon as
possible. It probably needs adjustment or
repair.
CAUTION
Do not continue driving with the ve-
hicle unchecked. It could result in se-
rious vehicle damage and possibly
personal injury.
Does your vehicle need
repairing?

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DOITYOURSELF MAINTENANCE
Introduction
Engine compartment overview 376
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Removing the engine compartment covers 377
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Fuse locations 378
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Do −it− yourself service precautions 379
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Positioning the jack 381
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Parts and tools 382
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SECTION 7 1

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1. Windshield and rear window washer
fluid tank
2. Brake fluid reservoir
3. Engine oil level dipstick
4. Gasoline engine coolant reservoir
5. Engine oil filler cap
6. Inverter coolant reservoir
7. Fuse blocks
8. Gasoline engine coolant radiator
9. Condenser
10. Inverter coolant radiator
11. Electric cooling fans
12. Auxiliary battery
Engine compartment overview

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High voltage current runs in the parts
and cables in the engine compartment.
Do not touch high voltage parts, cables
and connectors. For the locations of
high voltage parts and cables, see
“—High voltage components” on page
6 in Section 11.
CAUTION
Never touch, remove or disassemble
high voltage parts and cables. It can
cause severe burns or electric shock
that may result in death or serious
injury.
Front cover
: Clips
Rear cover
: Clip
: Hooks
(Hook up gently to remove.)
Removing the engine
compartment covers

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Removing clip
Installing clip
Before checking the fuse or replacing
the left front light bulbs, etc. in the
engine compartment, remove the engine
compartment covers as shown in the
illustrations:
1. Push the core of the clips and remove the clips.
2. Remove the cover.
Be careful not to lose the removed plastic
clips.
After checking the items, install the en-
gine compartment covers and insert the
plastic clips in their original positions.
NOTICE
After installing the engine compart-
ment covers, make sure the covers
are securely in their original posi-
tions.
Fuse locations

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CAUTION
Never touch, remove or disassemble
high voltage parts and cables.
Touching, removing or disassem-
bling those parts and cables can
cause severe burns or electric
shock that may result in death or
serious injury. For the locations of
high voltage parts and cables, see
“—High voltage components” on
page 6 in Section 11.
When the hybrid system is on, keep
hands, clothing, and tools away
from the moving fan. (Removing
rings, watches, and ties is advis-
able.)
Right after driving, the engine
compartment—the engine, radiator,
exhaust manifold and spark plug
boots, etc.—will be hot. So be care-
ful not to touch them. Oil, fluids
and spark plugs may also be hot.
If the radiator is hot, do not remove
the radiator cap or loosen the drain
plugs to prevent burning yourself.
Do not leave anything that may
burn easily, such as paper or rags,
in the engine compartment.
Do not smoke, cause sparks or al-
low open flames around fuel or the
battery. Their fumes are flammable.
When the hybrid system is operat-
ing with the “READY” light on, the
engine may suddenly start in some
cases. When you inspect the engine
compartment, be sure to turn off
the hybrid system.
Do not get under your vehicle with
just the body jack supporting it. Al-
ways use automotive jack stands or
other solid supports.
Be sure that the ignition is off if
you work near the electric cooling
fans or radiator grille. With the
ignition on, the electric cooling fans
will automatically start to run if the
engine coolant temperature is high
and/or the air conditioning is on.
Use eye protection whenever you
work on or under your vehicle
where you may be exposed to flying
or falling material, fluid spray, etc.
Brake fluid can harm your hands or
eyes and damage painted surfaces.
If fluid gets on your hands or in
your eyes, flush the affected area
with clean water immediately. If you
still feel uncomfortable with your
hands or eyes, go to the doctor.
Used engine oil contains potentially
harmful contaminants which may
cause skin disorders such as in-
flammation or skin cancer, so care
should be taken to avoid prolonged
and repeated contact with it. To re-
move used engine oil from your
skin, wash thoroughly with soap
and water.
Do not leave used oil within the
reach of children.
Dispose of used oil and filter only
in a safe and acceptable manner.
Do not dispose of used oil and fil-
ter in household trash, in sewers or
onto the ground. Call your dealer or
a service station for information
concerning recycling or disposal.
Be extremely cautious when work-
ing on the auxiliary battery. It con-
tains poisonous and corrosive
sulfuric acid.

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NOTICE
Remember that the auxiliary battery
and ignition cable carry high cur-
rents or voltages. Be careful of ac-
cidentally causing a short circuit.
 Add only “Toyota Super Long Life
Coolant” or similar high quality eth-
ylene glycol based nonsilicate,
nonamine, nonnitrite, and nonbo-
rate coolant with longlife hybrid
organic acid technology to fill the
radiator. “Toyota Super Long Life
Coolant” is a mixture of 50% cool-
ant and 50% deionized water (for
the U.S.A.) or 55% coolant and 45%
deionized water (for Canada).
 If you spill some of the coolant, be
sure to wash it off with water to
prevent it from damaging the parts
or paint.
 Do not allow dirt or anything else
to fall through the spark plug holes.
 Use only spark plugs of the speci-
fied type. Using other types will
cause engine damage, loss of per-
formance or radio noise.
Do not reuse iridiumtipped spark
plugs by cleaning or regapping.
 Do not drive with the air cleaner
filter removed, or excessive engine
wear could result. Also backfiring
could cause a fire in the engine
compartment.
 Be careful not to scratch the glass
surface with the wiper frame.
 When closing the engine hood,
check to see that you have not for-
gotten any tools, rags, etc.
Front
Rear (front wheel drive models)
Positioning the jack

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2006 HIGHLANDER (Hybrid) from Mar. ’05 Prod. (OM48530U)
Rear (all wheel drive models)
When jacking up your vehicle with the
jack, position the jack correctly as
shown in the illustrations.
CAUTION
When jacking, be sure to observe the
following to reduce the possibility of
personal injury:
Follow jacking instructions.
Do not put any part of your body
under the vehicle supported by the
jack. Personal injury may occur.
Do not start the hybrid system
while your vehicle is supported by
the jack.
Stop the vehicle on a level firm
ground, firmly set the parking brake
and put the hybrid transmission in
“P”. Block the wheels on the oppo-
site side of the jack up point if
necessary.
Make sure to set the jack properly
in the jack point. Raising the ve-
hicle with jack improperly posi-
tioned will damage the vehicle or
may allow the vehicle to fall off the
jack and cause personal injury.
Never get under the vehicle when
the vehicle is supported by the jack
alone; use vehicle support stands.
Do not raise the vehicle with some-
one in the vehicle.
When raising the vehicle, do not
place any objects on top of or un-
derneath the jack.
NOTICE
Make sure to place the jack correctly,
or your vehicle may be damaged.
Here is a list of parts and tools you will
need to perform do−it−yourself mainte-
nance. Remember all Toyota parts are de-
signed in metric sizes, so your tools must
be metric.
CHECKING THE ENGINE OIL LEVEL
Parts (if level is low):
“Toyota Genuine Motor Oil” or equiva-
lent
See page 386 in Section 7− 2 for de-
tails about engine oil selection.
Tools:
Rag or paper towel
Funnel (only for adding oil)
CHECKING THE COOLANT LEVEL
Parts (if level is low):
“Toyota Super Long Life Coolant” or
similar high quality ethylene glycol
based non −silicate, non −amine, non− ni-
trite, and non −borate coolant with long −
life hybrid organic acid technology.
“Toyota Super Long Life Coolant” is a
mixture of 50% coolant and 50% deion-
ized water (for the U.S.A.) or 55%
coolant and 45% deionized water (for
Canada).
Parts and tools

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DOITYOURSELF MAINTENANCE
Engine and Chassis
Checking the engine oil level 386
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Checking the coolant level 388
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Checking the radiators and condenser 390
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Checking brake fluid 390
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Checking tire inflation pressure 391
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Checking and replacing tires 393
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Rotating tires 395
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Installing snow tires and chains 396
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Replacing wheels 397
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Aluminum wheel precautions 398
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SECTION 7 2

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2006 HIGHLANDER (Hybrid) from Mar. ’05 Prod. (OM48530U)
Low level Full level
Add oil O.K. Too full
With the hybrid system at operating
temperature and turned off, check the
oil level on the dipstick. 1. To get a correct reading, the vehicle should be on level ground. After turning
off the hybrid system, wait a few min-
utes for the oil to drain back into the
bottom of the engine.
2. Pull the dipstick out, hold a rag under the end and wipe it clean.
3. Reinsert the dipstick—push it in as far as it will go, or the reading will not be
correct.
4. Pull the dipstick out and look at the oil level while holding a rag under the
end.
CAUTION
Be careful not to touch the hot ex-
haust manifold.
NOTICE
Be careful not to drop engine oil on
the vehicle components.
 To avoid drops of the engine oil
falling when you pull out the engine
oil dipstick, make sure to hold a
rag under the dipstick.
If the oil level is below or only slightly
above the low level, add engine oil of
the same type as already in the engine.
Remove the oil filler cap and add engine
oil in small quantities at a time, checking
the dipstick. We recommend that you use
a funnel when adding oil.
The approximate quantity of oil needed to
raise the level between low and full on the
dipstick is indicated as follows:
1.5 L (1.6 qt., 1.3 lmp. qt.)
For the engine oil capacity, see “Service
specifications” on page 412 in Section 8. When the level reaches within the correct
range, install the filler cap hand−
tight.
NOTICE
Be careful not to spill engine oil on
the vehicle components.
 Avoid overfilling, or the engine
could be damaged.
 Check the oil level on the dipstick
once again after adding the oil.
Checking the engine oil level