engine TOYOTA HIGHLANDER HYBRID 2020 (in English) Repair Manual

4617-2. Steps to take in an emergency
HIGHLANDER HV_U
7
When trouble arises
■Hybrid system overheat warning light*(warning buzzer)
*: This light illuminat es on the multi-information display.
■Charging system warning light*
*: This light illuminates on the multi-information display.
■Low engine oil pressure warning light* (warning buzzer)
*: This light illuminates on the multi-information display.
■Malfunction indicator lamp
Warning lightDetails/Actions
Indicates the hybrid s ystem has overheated
 Stop the vehicle in a safe place.
Handling method ( P.498)
Warning lightDetails/Actions
Indicates a malfunction in the vehicle’s charging system
 Immediately stop the vehicle in a safe place and con-
tact your Toyota dealer.
Warning lightDetails/Actions
Indicates that the engine oil pressure is too low
 Immediately stop the vehicle in a safe place and con-
tact your Toyota dealer.
Warning lightDetails/Actions
(U.S.A.)
or
(Canada)
Indicates a malfunction in:
The hybrid system;
 The electronic engine control system; or
 The electronic thrott le control system;
 Immediately stop the vehicle in a safe place and con-
tact your Toyota dealer.

4717-2. Steps to take in an emergency
HIGHLANDER HV_U
7
When trouble arises
The warning lights and warning buzzers operate as follows depend-
ing on the content of the message. If a message indicates the need
for inspection by a dealer, have the vehicle inspected by your To y o t a
dealer immediately.
*: A buzzer sounds the first time a message is shown on the multi-informa-
tion display.
■Warning messages
The warning messages explained
below may differ from the actual
messages according to operation
conditions and vehicle specifica-
tions.
■Warning buzzer
In some cases, the buzzer may not
be heard due to being in a noisy
location or audio sound.
■If “Engine Oil Level Low Add or
Replace” is displayed
The engine oil level is low. Check
the level of the engine oil, and add if
necessary.
This message may appear if the
vehicle is stopped on a slope. Move
the vehicle to a l evel surface and
check to see if the message disap-
pears.
Messages and warnings
Warning lightWarning
buzzer
*Warning
-Sounds
 Indicates an important situation, such as
when a system relate d to driving is mal-
functioning or that danger may result if
the correction procedure is not per-
formed
 Indicates a situation, such as when dam-
age to the vehicle or danger may result
Comes on or
flashesSounds
Indicates an importan t situation, such as
when the systems shown on the
multi-information display may be malfunc-
tioning
-Does not sound
 Indicates a condition, such as malfunc-
tion of electrical components, their condi-
tion, or indicates the need for
maintenance
 Indicates a situatio n, such as when an
operation has been performed incor-
rectly, or indicates how to perform an
operation correctly

4737-2. Steps to take in an emergency
HIGHLANDER HV_U
7
When trouble arises
■If “Front Camera Unavailable”
or “Front Camera Unavailable
See Owner's Manual” is dis-
played
The following sys tems may be sus-
pended until the pr oblem shown in
the message is resolved. ( P.247,
466)
●PCS (Pre-Collision system)
●LTA (Lane Tracing Assist)
●Automatic High Beam
●RSA (Road Sign Assist) (if
equipped)
●Dynamic radar cruise control with
full-speed range
■If “AWD System Overheated
Switching to 2WD Mode” or
“AWD System Overheated 2WD
Mode Engaged” is displayed
(AWD models)
This message may be displayed
when driving under extremely high
load conditions.
Drive the vehicle at low speeds and
stop the vehicle in a safe place with
the engine running until the mes-
sage is cleared.
If the message is not cleared, have
the vehicle inspected by your Toyota
dealer.
■If “Check Fuel Cap” is dis-
played
The fuel tank cap is not properly
installed. Correctly install the fuel
tank cap.
■If “Maintenance Required
Soon” is displayed
Indicates that all maintenance
according to the dr iven distance on
the maintenance schedule
* should
be performed soon.
Comes on approximately 4500
miles (7200 km) after the message
has been reset. If necessary, per-
form maintenance. Please reset the
message after the maintenance is
performed. ( P.401)
*: Refer to the separate “Scheduled
Maintenance” or “Owner’s Man-
ual Supplement” for the mainte-
nance interval applicable to your
vehicle.
■If “Maintenance Required Visit
Your Dealer” is displayed
Indicates that all maintenance is
required to correspond to the driven
distance on the maintenance sched-
ule
*.
Comes on approximately 5000
miles (8000 km) after the message
has been reset. (The indicator will
not work properly unless the mes-
sage has been rese t.) Perform the
necessary maintenance. Please
reset the message after the mainte-
nance is performed. ( P.401)
*: Refer to the separate “Scheduled
Maintenance” or “Owner’s Man-
ual Supplement” for the mainte-
nance interval applicable to your
vehicle.
■If a message that indicates the
need for visiting your Toyota
dealer is displayed
The system or part shown on the
multi-information di splay is malfunc-
tioning. Have the vehicle inspected
by your Toyota dealer immediately.
■If a message that indicates the
need for referring to Owner’s
Manual is displayed
●If any of the following messages
are shown on the multi-informa-
tion display, it may indicate a mal-
function. Immediately stop the
vehicle and contact your Toyota
dealer.
• “Braking Power Low Stop in a Safe Place See Owner's Manual”
• “Oil Pressure Low Stop in a Safe
Place See Owner's Manual”
• “Charging System Malfunction Stop in a Safe Place See Owner's
Manual”
• “Hybrid System Stopped”

4747-2. Steps to take in an emergency
HIGHLANDER HV_U• “Engine Stopped”
• “Stop in a Safe Place See Owner's
Manual”
• “Shift to P See Owner's Manual”
●If any of the following messages
are shown on the multi-informa-
tion display, it may indicate a mal-
function. Have the vehicle
inspected by you r Toyota dealer
immediately.
• “Hybrid System Malfunction”
• “Check Engine”
• “Hybrid Battery System Malfunc- tion”
• “Accelerator Syst em Malfunction”
• “Smart Key System Malfunction See Owner's Manual”
●If any of the following messages
are shown on the multi-informa-
tion display, follow the instruc-
tions.
• “Engine Coolant Temp High Stop
in a Safe Place See Owner's Man-
ual” ( P.497)
• “Maintenance Required for Trac-
tion Battery Cooling Parts See
Owner's Manual” ( P.497)
 Stop the vehicle in a safe
place on a hard, flat surface.
 Set the parking brake.
 Shift the shift lever to P.
 Stop the hybrid system.
 Turn on the emergency flash-
ers. ( P.452)
 Turn off the power back door
system. ( P.526)
NOTICE
■If “High Power Consumption
Partial Limit on AC/Heater
Operation” is displayed fre-
quently
There is a possible malfunction
relating to the ch arging system or
the 12-volt battery may be deteri-
orating. Have the vehicle
inspected by your Toyota dealer.
If you have a flat tire
Your vehicle is equipped
with a spare tire. The flat tire
can be replaced with the
spare tire.
For details about tires:
 P. 4 1 8
WA R N I N G
■If you have a flat tire
Do not continue driving with a flat
tire.
Driving even a sho rt distance with
a flat tire can damage the tire and
the wheel beyond repair, which
could result in an accident.
Before jacking up the
vehicle

4847-2. Steps to take in an emergency
HIGHLANDER HV_U
7Confirm it is not loose after
tightening:
1 Push and pull the tire
2 Try rotating
Visually check to ensure tire is not
hung on surrounding parts.
If looseness or misassembly exists,
repeat steps 2 to 7.
8 Repeat step 7, any time the
tire is lowered or disturbed.
9 Stow the jack and all tools.
■The compact spare tire
●The compact spare tire is identi-
fied by the label “TEMPORARY
USE ONLY” on the tire sidewall.
Use the compact spare tire tempo-
rarily, and only in an emergency.
●Make sure to check the tire infla-
tion pressure of the compact
spare tire. ( P.511)
■When using the compact spare
tire
As the compact sp are tire is not
equipped with a tire pressure warn-
ing valve and transmitter, low infla-
tion pressur e of the spar e tire will
not be indicated by the tire pressure
warning system. Also, if you replace
the compact spare tire after the tire
pressure warning light comes on,
the light remains on.
■When the compact spare tire is
equipped
When driving wit h the compact spare tire installed, the vehicle
height will be diffe
rent than when
driving with standard tires.
■If you have a flat front tire on a
road covered with snow or ice
Install the compact spare tire on one
of the rear wheels of the vehicle.
Perform the following steps and fit
tire chains to the front tires:
1 Replace a rear tire with the com-
pact spare tire.
2 Replace the flat front tire with the
tire removed from the rear of the
vehicle.
3 Fit tire chains to the front tires.
WA R N I N G
■When using the compact
spare tire
●Remember that the compact
spare tire provided is specifi-
cally designed for use with your
vehicle. Do not use your com-
pact spare tire on another vehi-
cle.
●Do not use more than one com-
pact spare tire simultaneously.
●Replace the comp act spare tire
with a standard tire as soon as
possible.
●Avoid sudden acceleration,
abrupt steering, sudden brak-
ing and shifting operations that
cause sudden engine braking.
■When the compact spare tire
is attached
The vehicle speed may not be
correctly detected, and the follow-
ing systems may not operate cor-
rectly:
• ABS & Brake assist
• VSC
•TRAC
• EPS

4937-2. Steps to take in an emergency
HIGHLANDER HV_U
7
When trouble arises
on the second vehicle and connect the clamp at the other end of
the negative cable to .
Exclusive jump starting terminal (your vehicle)
Positive (+) battery terminal (second vehicle)
Negative (-) battery term inal (second vehicle)
Solid, stationary, unpainted metallic point away from the exclu sive
jump starting terminal and any m oving parts as shown in the illus-
tration
5 Start the engine of the sec-
ond vehicle. Increase the
engine speed slightly and
maintain at that level for
approximately 5 minutes to
recharge the 12-volt battery
of your vehicle.
6 Open and close any of the
doors of your vehicle with the
power switch OFF.
7 Maintain the engine speed of
the second vehicle and start
the hybrid system of your
vehicle by turning the power
switch to ON.
8 Make sure the “READY” indi-
cator comes on. If the indica- tor light does not come on,
contact your Toyota dealer.
9 Once the hybrid system has
started, remove the jumper
cables in the exact reverse
order from which they were
connected.
10Close the exclusive jump starting terminal cover, and
reinstall the fuse box cover to
its original position.
Once the hybrid system starts,
have the vehicle inspected at
your Toyota dealer as soon as
possible.

4977-2. Steps to take in an emergency
HIGHLANDER HV_U
7
When trouble arises
If the engine coolant tempera-
ture gauge enters the red
zone or “Engine Coolant
Temp High Stop in a Safe
Place See Owner’s Manual”
is shown on the multi-informa-
tion display
1 Stop the vehicle in a safe
place and turn off the air con-
ditioning system, and then
stop the hybrid system.
2 If you see steam:
Carefully lift the hood after the steam subsides.
If you do not see steam:
Carefully lift the hood.
3 After the hybrid system has
cooled down sufficiently,
inspect the hoses and radia-
tor core (radiator) for any
leaks.
If a large amount of coolant leaks,
immediately contact your Toyota
dealer.
Radiator
Cooling fan
4 The coolant level is satisfac-
tory if it is between the
“FULL” and “LOW” lines on
the reservoir.
Reservoir
“FULL” line
“LOW” line
Radiator cap
If your vehicle over-
heats
The following may indicate
that your vehicle is over-
heating.
The needle of the engine
coolant temperature gauge
( P.89) enters the red zone
or a loss of hybrid system
power is experienced. (For
example, the vehicle speed
does not increase.)
 “Engine Coolant Temp High
Stop in a Safe Place See
Owner’s Manual” or “Hybrid
System Overheated Output
Power Reduced” is shown
on the multi-information dis-
play.
 Steam comes out from
under the hood.
Correction procedures

4987-2. Steps to take in an emergency
HIGHLANDER HV_U
5Add coolant if necessary.
Water can be used in an emer-
gency if coolant is unavailable.
6Start the hybrid system and
turn the air conditioning sys-
tem on to check that the radi-
ator cooling fan operates and
to check for coolant leaks
from the radiator or hoses.
The fan operates when the air con-
ditioning system is turned on imme-
diately after a cold start. Confirm
that the fan is op erating by check-
ing the fan sound and air flow. If it is
difficult to check th ese, turn the air
conditioning system on and off
repeatedly. (The fan may not oper-
ate in freezing temperatures.)
7 If the fan is not operating:
Stop the hybrid system
immediately and contact your
Toyota dealer.
If the fan is operating:
Have the vehicle inspected at
the nearest Toyota dealer.
8 Check if “Engine Coolant
Temp High Stop in a Safe
Place See Owner's Manual”
is shown on the multi-infor-
mation display.
If the message does not disappear:
Stop the hybrid system and contact
your Toyota dealer. If the message is not displayed:
Have the vehicle inspected at the
nearest Toyota dealer.
If “Hybrid System Over-
heated Output Power
Reduced” is shown on the
multi-information display
1 Stop the vehicle in a safe
place.
2 Stop the hybrid system and
carefully lift the hood.
3 After the hybrid system has
cooled down, inspect the
hoses and radiator core (radi-
ator) for any leaks.
If a large amount of coolant leaks,
immediately contact your Toyota
dealer.
Radiator
Cooling fan
4 The coolant level is satisfac-
tory if it is between the

4997-2. Steps to take in an emergency
HIGHLANDER HV_U
7
When trouble arises
“FULL” and “LOW” lines on
the reservoir.
Reservoir
“FULL” line
“LOW” line
5 Add coolant if necessary.
Water can be used in an emer-
gency if coolant is unavailable.
6After stopping the hybrid sys-
tem and waiting for 5 minutes
or more, start the hybrid sys-
tem again and check if
“Hybrid System Overheated
Output Power Reduced” is
shown on the for the
multi-information display.
If the message does not disappear:
Stop the hybrid system and contact
your Toyota dealer.
If the message is not displayed:
The hybrid system temperature has
dropped and the vehicle may be
driven normally. However, if the m
essage appears
again frequently, contact your Toy-
ota dealer.
WA R N I N G
■When inspecting under the
hood of your vehicle
Observe the following precau-
tions.
Failure to do so may result in seri-
ous injury such as burns.
●If steam is seen coming from
under the hood, do not open the
hood until the steam has sub-
sided. The engine compart-
ment may be very hot.
●After the hybrid system has
been turned off , check that the
“READY” indicator is off.
When the hybrid system is oper-
ating, the gasoline engine may
automatically start, or the cool-
ing fan may suddenly operate
even if the gasoline engine
stops. Do not touch or approach
rotating parts such as the fan,
which may lead to fingers or
clothing (especially a tie, a scarf
or a muffler) getting caught,
resulting in serious injury.
●Do not loosen the radiator cap
and the coolant reservoir caps
while the hybrid system and
radiator are hot.
High temperature steam or
coolant could spray out.
NOTICE
■When adding engine/power
control unit coolant
Add coolant slowly after the
hybrid system has cooled down
sufficiently. Adding cool coolant to
a hot hybrid system too quickly
can cause damage to the hybrid
system.

5068-1. Specifications
HIGHLANDER HV_Uness.
7
Install the dash panel insula-
tor pad.
8 Return the carpet to its origi-
nal position.
Install the 2 holes of the carpet to
the wire harness clamps.
9Install the trim.
Align the clip, claw and bolt hole and install the trim with the nut.
10Install the scuff plate.
Insert the 2 guides
at the front of
the scuff plate into the trim, align
the 7 claws with the wire harness
clamps, and install the scuff plate.
Left-hand side center pillar
This number is also on the Certifi-
cation Label.
■Engine number
The engine number is stamped
on the engine block as shown.