suspension TOYOTA HIGHLANDER 2001 Service User Guide

Explanation of Maintenance Items
38
Engine Valve Clearance
Inspect for excessive lifter noise and engine vibration and adjust if necessary.
A qualified technician should perform this operation.
Exhaust Pipes and Mountings
Visually inspect the exhaust pipes, muffler and hangers for cracks, deterioration
and damage. Start the engine and listen carefully for any exhaust gas leakage.
Tighten connections or replace parts as necessary.
Fuel Lines and Connections, Fuel Tank Band and
Fuel Tank Vapor Vent System Hoses
Visually inspect for corrosion, damage, cracks and loose or leaking connections.
Tighten connections or replace parts as necessary.
Fuel Tank Cap Gasket
Visually inspect for cracks, deterioration and damage and replace if necessary.
Nuts and Bolts on Chassis and Body
Retighten the seatmounting bolts and front/rear suspension member retaining
bolts to specified torque.
Propeller Shaft
Lubricate the propeller shaft spiders and slide yokes with lithiumbase chassis grease
and the double cardan joint with molybdenumdisulfide lithiumbase chassis grease,
and retorque the bolt. Only a qualified technician should retorque the bolt.
Radiator Core and Condenser
Inspect for debris and signs of damage. Have any problem repaired immediately
by a qualified technician.
Spark Plugs
Replace at specified intervals. Install new plugs of the same type as originally
equipped. A qualified technician should perform this operation.
Steering Gear Box
Inspect for signs of leakage. If you discover any leakage, have it repaired imme
diately by a qualified technician.

- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-219
409 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
DTC P0504 BRAKE SWITCH ºAº/ºBº CORRELATION
CIRCUIT DESCRIPTION
In addition to turning on the stop lamp, the stop lamp switch signals are used for a variety of engine, transmis-
sion, and suspension functions as well as being an input for diagnostic checks. It is important that the switch
operates properly, therefore this switch is designed with two complementary signal outputs: STP and ST1.
The ECM analyzes these signal outputs to detect malfunctions in the stop lamp switch.
HINT:
Normal condition is as shown in the table.
SignalBrake pedal releasedIn transitionBrake pedal depressed
STPOFFONON
ST1ONONOFF
DTC No.DTC Detection ConditionTrouble Area
P0504
Conditions (a), (b) and (c) continue for 0.5 seconds or more:
(a) Ignition switch ON
(b) Brake pedal released
(c) STP signal is OFF when the ST1 signal is OFF
Short in stop lamp switch signal circuit

STOP fuse

Stop lamp switch

ECM
05EVK-05

100IU-03
A93427N´m (kgf´cm, ft´lbf) : Specified torque
7.9 (81, 70 in.Vlbf)x 3
V-Bank Cover Sub-assy
Vacuum Hose
Air Cleaner Filter Element
Sub-assy Air Cleaner Cap Sub-assyMAF Meter
Connector Fuel Vapor Feed Hose Assy
Vacuum Hose
w/ Performance Rod:
Front Suspension Upper Brace Center
Spacer
80 (815, 59)
Spacer
x 2
x 2
80 (815, 59)
10-16
- ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (3MZ-FE)
2374 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
THROTTLE BODY ASSY (3MZ-FE)
COMPONENTS

260H9-02
G29259
- FRONT SUSPENSIONSHOCK ABSORBER ASSY FRONT LH
26-17
2938 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
DISPOSAL
HINT:
Dispose of the RH side by following the same procedures as with the LH side.
1. DISPOSE OF SHOCK ABSORBER ASSY FRONT LH
(a) Fully extend the shock absorber rod.
(b) Using a drill, make a hole in the cylinder as shown in the
illustration to discharge the gas inside.
CAUTION:

Be careful when drilling because shards of metal may
fly about. Always use the proper safety equipment.

The gas is colorless, odorless and non-poisonous.

INTRODUCTIONIN-15
HANDLING PRECAUTIONS ON RELATED COMPONENTS
1. BRAKE SYSTEM
The brake system is one of the most important safety components. Always follow the directions and
notes given in brake (32) section of the repair manual for the relevant model when handling brake system
parts.
NOTICE: When repairing the brake master cylinder or TRAC system, bleed the air out of the TRAC sys-
tem.
2. DRIVE TRAIN AND CHASSIS
The drive train and chassis are components that can have great effects on the running performance and
vibration resistance of the vehicle. After installing components in the sections listed in the table below,
perform alignments to ensure correct mounting angles and dimensions. Particularly accurate repair of
the body must also be done to ensure correct alignment.
HINT: Correct procedures and special tools are required for alignment. Always follow the directions giv-
en in the repair manual for the relevant model during alignment and section DI of this section.
Component to be alignedSection of repair manual
for relevant model
Front WheelsFront Suspension (26) section
Rear WheelsRear Suspension (27) section
Propeller ShaftPropeller Shaft (30) section
3. COMPONENTS ADJACENT TO THE BODY PANELS
Various types of component parts are mounted directly on or adjacently to the body panels. Strictly ob-
serve the following precautions to prevent damaging these components and the body panels during han-
dling.

Before repairing the body panels, remove their components or apply protective covers over the com-
ponents.

Before prying components off using a screwdriver or a scraper, etc., attach protective tape to the tool
tip or blade to prevent damaging the components and the body paint.

Before removing components from the outer surface of the body, attach protective tape to the body to
ensure no damage to painted areas.
HINT: Apply touch-up paint to any damaged paint surfaces.

Before drilling or cutting sections, make sure that there are no wires, etc. on the reverse side.
4. ECU (ELECTRONIC CONTROL UNIT)
Many ECUs are mounted in this vehicle.
Take the following precautions during body repair to prevent damage to the ECUs.

Before starting electric welding operations, disconnect the negative (-) terminal cable from the bat-
tery.
When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio
systems will be cancelled. So before starting work, make a record of the contents memorized by each
memory system. Then when work is finished, reset the clock and audio systems as before.
When the vehicle has tilt and telescopic steering, power seat and outside rear view mirror, which are
all equipped with memory function, it is not possible to make a record of the memory contents.
So when the operation is finished, it will be necessary to explain this fact to the customer, and request
the customer to adjust the features and reset the memory.

Do not expose the ECUs to ambient temperatures above 80C (176F).
NOTICE: If it is possible the ambient temperature may reach 80C (176F) or more, remove the ECUs
from the vehicle before starting work.

Be careful not to drop the ECUs and not to apply physical shocks to them.

010QO-02
- INTRODUCTIONTERMS
01-41
41 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
TERMS
ABBREVIATIONS USED IN MANUAL
AbbreviationsMeaning
ABSAnti-Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir-Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
Approx.Approximately
ASSYAssembly
A/T, ATMAutomatic Transmission
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi-Level
B/SBore-Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
CANController Area Network
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current

- INTRODUCTIONTERMS
01-43
43 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)Abbreviations Meaning
H-FUSEHigh Current Fuse
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HSGHousing
HTHard Top
HWSHeated Windshield System
ICIntegrated Circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
ISCIdle Speed Control
J/BJunction Block
J/CJunction Connector
KDKick-Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft-Hand
LHDLeft-Hand Drive
L/H/WLength, Height, Width
LLCLong-Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAPManifold Absolute Pressure
MAX.Maximum
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MG1Motor Generator No.1
MG2Motor Generator No.2
MPMultipurpose
MPIMultipoint Electronic Injection
MPXMultiplex Communication System
M/T, MTMManual Transmission (Transaxle)
MTMount
MTGMounting
NNeutral
NANatural Aspiration
No.Number
O2SOxygen Sensor
O/DOverdrive

01-44
- INTRODUCTIONTERMS
44 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)Abbreviations Meaning
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
ORVROn-board Refilling Vapor Recovery
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
PKBParking Brake
PPSProgressive Power Steering
PTCPositive Temperature Coefficient
PSPower Steering
PTOPower Take-Of f
P/WPower Window
R & PRack And Pinion
RAMRandom Access Memory
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight-Hand
RHDRight-Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRSRigid Rear Suspension
RWDRear-Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold-Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection
TCTurbocharger
TCCSTOYOTA Computer-Controlled System
TCVTiming Control Valve
TDCTop Dead Center
TEMP.Temperature
TEMSTOYOTA Electronic Modulated Suspension

D25532
- INTRODUCTIONREPAIR INSTRUCTION
01-19
19 Author
: Date
:
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.

2701I-1 1
- REAR SUSPENSIONREAR SUSPENSION SYSTEM
27-1
2949 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
REAR SUSPENSION SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below, with suspected areas listed in numerical order, to determine the cause of the problem.
Inspect and repair or replace parts as necessary according to the steps on the following pages.
SymptomSuspected AreaSee page
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)-
27-7
27-7
Sways/pitches
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn)28-1
27-27
27-29
27-7
Rear wheel shimmy
1. Tire (Worn or improperly inflated)
2. Wheel (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Hub bearing (Worn)28-1
28-1
27-7
26-7
27-5
30-3
Abnormal tire wear
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn)
4. Suspension parts (Worn)28-1
26-7
27-5
27-7
-