TOYOTA HIGHLANDER 2001 Service Repair Manual

'05 HIGHLANDER_U (L/O 0409)
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
Publication No. OM48570U
Part No. 01999-48570
Printed in Japan 01- 0411- 00
Quick index

If a service reminder indicator or warning buzzer comes on 135. . . . . . . .

If your vehicle will not start 332. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

If your engine stalls while driving 335. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

If your vehicle overheats 336. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

If you have a flat tire 337. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

If your vehicle needs to be towed 349. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tips for driving during break- in period 291. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to start the engine 318. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General maintenance 367. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Complete index NO TAG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas station information
Fuel type:
2AZ- FE engine: UNLEADED gasoline, Octane Rating 87
(Research Octane Number 91) or higher
3MZ- FE engine: UNLEADED gasoline, Octane Rating 87
(Research Octane Number 91) or higher
For improved vehicle performance, the use of premium unleaded
gasoline with an Octane Rating of 91 (Research Octane Number 96)
or higher is recommended.
See page 291 for detailed information.
Fuel tank capacity:
72.5 L (19.1 gal., 16.0 Imp.gal.)
Engine oil:
API grade SL Energy- Conservingº or ILSAC multigrade engine oil is
recommended.
See page 381 for detailed information.
Tire information: See pages 385 through 393.
Tire inflation pressure: See page 410.
U-8
C

BODY DIMENSIONS
Three-dimensional
distanceCenter-to-center
straight-line
distance
Two-dimensional
distanceCenter-to-center
Horizontal distance
in forward / rearward
Vertical distance
in centerVertical distance
in lower surface
Imaginary Standard Line
Under Surface of
The Rocker Panel
Imaginary Standard Line
DI-1
GENERAL INFORMATION
1. BASIC DIMENSIONS
(a) There are two types of dimensions in the diagram.
(1) (Three-dimensional distance)

Straight-line distance between the centers of two
measuring points.
(2) (Two-dimensional distance)

Horizontal distance in forward / rearward between the
centers of two measuring points.

The height from an imaginary standard line.
(b) In cases in which only one dimension is given, left and right
are symmetrical.
(c) The dimensions in the following drawing indicate actual dis-
tance. Therefore, please use the dimensions as a refer-
ence.
(d) The line that connects the places listed below is the imagi-
nary standard line when measuring the height. (The dimen-
sions are printed in the text.)
SYMBOLName
1The place that was lowered A mm from the under surface of
the rocker panel centered on the front jack up point.
2The place that was lowered B mm from the under surface of
the rocker panel centered between 1 and 3.
3The place that was lowered C mm from the under surface of
the rocker panel centered on the rear jack up point.

Plate Looseness
Body Looseness
Pointer Looseness
Pointer
Master Gauge
Wrong Correct
Pointer
BODY DIMENSIONSDI-2
2. MEASURING
(a) Basically, all measurements are to be done with a tracking
gauge. For portions where it is not possible to use a track-
ing gauge, a tape measure should be used.
(b) Use only a tracking gauge that has no looseness in the
body, measuring plate, or pointers.
HINT:
1) The height of the left and right pointers must be equal.
2) Always calibrate the tracking gauge before measuring
or after adjusting the pointer height.
3) Take care not to drop the tracking gauge or otherwise
shock it.
4) Confirm that the pointers are securely in the holes.
(c) When using a tape measure, avoid twists and bends in the
tape.

F10004
F10001A
F10002A
F10003A
Glass Cover
Seat Cover
WRONG
WRONG
INTRODUCTION
GENERAL REPAIR INSTRUCTIONS
1. WORK PRECAUTIONS
(a) VEHICLE PROTECTION
(1) When welding, protect the painted surfaces, windows,
seats and carpet with heat resistant, fire-proof covers.
(b) SAFETY
(1) Never stand in direct line with the chain when using a
puller on the body or frame, and be sure to attach a
safety cable.
(2) Before performing repair work, check for fuel leaks.
If a leak is found, be sure to close the opening totally.
(3) If it is necessary to use a flame in the area of the fuel
tank, first remove the tank and plug the fuel line.
(c) SAFETY WORK CLOTHES
(1) In addition to the usual mechanic's wear, cap and
safety shoes, the appropriate gloves, head protector,
glasses, ear plugs, face protector, dust-prevention
mask, etc. should be worn as the situation demands.
CodeName
ADust-Prevention Mask
BFace Protector
CEye Protector
DSafety Shoes
EWelder's Glasses
FEar Plugs
GHead Protector
HWelder's Gloves

INTRODUCTION
2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS
(1) The repair procedure for plastic body parts must conform with the type of plastic material.
(2) Plastic body parts are identified by the codes in the following table.
(3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint-
ing etc.), consideration must be given to the property of the plastic.
CodeMaterial
name
Heat*
resistant
temperature
limit C (F)Resistance to
alcohol or gasolineNotes
AASAcrylonitrile
Acrylic Styrene80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid gasoline and organic
or aromatic solvents.
ABSAcrylonitrile
Butadiene Styrene80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid gasoline and organic
or aromatic solvents.
AESAcrylonitrile
Ethylene Styrene80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid gasoline and organic
or aromatic solvents.
ASA
Acrylonitrile
Styrene
Acrylate80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid gasoline and organic
or aromatic solvents.
CABCellulose
Acetate80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid gasoline and organic
or aromatic solvents.
EPDMEthylene
Propylene100
(212)Alcohol is harmless.
Gasoline is harmless if applied only for
short time in small amounts.Most solvents are harmless
but avoid dipping in gasoline,
solvents, etc.
FRP
Fiber
Reinforced
Plastics180
(356)Alcohol and gasoline are harmless.Avoid alkali.
EVAEthylene
Acetate70
(158)Alcohol is harmless if applid only for short
time in small amounts (e.g., quick wiping
to remove grease).Avoid gasoline and organic
or aromatic solvents.
PAPolyamide
(Nylon)80
(176)Alcohol and gasoline are harmless.Avoid battery acid.
PBTPolybutylene
Terephthalate160
(320)Alcohol and gasoline are harmless.Most solvents are harmless.
PCPolycarbonate120
(248)Alcohol is harmless.
Avoid gasoline brake fluid,
wax, wax removers and
organic solvents. Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.

INTRODUCTION
CodeMaterial
name
Heat*
resistant
temperature
limit C (F)Resistance to
alcohol or gasolineNotes
PEPolyethylene80
(176)Alcohol and gasoline are harmless.Most solvents are harmless.
PETPolyethylene
Terephthalate75
(167)Alcohol and gasoline are harmless.Avoid dipping in water.
PMMAPolymethyl
Methacrylate80
(176)Alcohol is harmless if applied only for
short time in small amounts.Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
POMPolyoxymethylene
(Polyacetal)100
(212)Alcohol and gasoline are harmless.Most solvents are harmless.
PPPolypropylene80
(176)Alcohol and gasoline are harmless.Most solvents are harmless.
PPO
Modified
Polyphenylene
Oxide100
(212)Alcohol is harmless.
Gasoline is harmless if
applied only for quick wiping
to remove grease.
PSPolystyrene60
(140)Alcohol and gasoline are harmless if
applied only for short time in small
amounts.Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
PURPolyurethane80
(176)Alcohol is harmless if applied only for very
short time in small amounts (e.g., quick
wiping to remove grease).Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
PVCPolyvinylchloride
(Vinyl)80
(176)
Alcohol and gasoline are harmless if
applied only for short time in small
amounts (e.g., quick wiping to remove
grease).Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
SANStyrene
Acrylonitrile80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid dipping or immersing
in alcohol, gasoline, solvents
etc.
TPOThermoplastic
Olefine80
(176)Alcohol is harmless.
Gasoline is harmless if applied only for
short time in small amounts.Most solvents are harmless
but avoid dipping in gasoline,
solvents, etc.
TPUThermoplastic
Polyurethane80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
TSOP
TOYOTA
Super
Olefine Polymer80
(176)Alcohol and gasoline are harmless.Most solvents are harmless.
UPUnsaturated
Polyester11 0
(233)Alcohol and gasoline are harmless.Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.

INTRODUCTION
3. LOCATION OF PLASTIC BODY PARTS
Parts NameCode
Radiator GrilleABS
HeadlightPC / PP
Front Bumper CoverTSOP
Front Bumper Hole CoverTSOP
Fog LightPC
Front Fender MudguardPP / EPDM
Outer Rear View MirrorABS / PA
Cowl Top Ventilator LouverPP
Door Outside Handle (Front, Rear)PC / PA
PA
Door Outside Moulding (Front, Rear)PP
Quarter Panel MudguardPP / EPDM
Rear Bumper CoverTSOP
Back Door Outside GarnishABS
Back Door Outside HandlePA
Rear Combination LightPMMA / AAS
License Plate LightPC / PA
Center Stop LightPC
Rear SpoilerABS
HINT:

Resin material differs with model.
/ Made up of 2 or more kinds of materials.

9900X-21
99-4
- MAINTENANCEUNDER HOOD
3784 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
UNDER HOOD
GENERAL MAINTENANCE
1. GENERAL NOTES

Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.

Every service item in the periodic maintenance schedule must be performed.

Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

Maintenance service after the last period should be performed at the same interval as before unless
noted.

Failure to do even one of the items can cause the engine to run poorly and/or increase the exhaust
emissions.
2. WINDSHIELD WASHER FLUID
(a) Check that there is sufficient fluid in the tank.
3. ENGINE COOLANT LEVEL
(a) Check that the coolant level is between the LEVEL lines on the see-through reservoir at normal tem-
perature (20°C (68°F)).
4. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not blocked by leaves, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or loose connections.
5. BATTERY ELECTROLYTE LEVEL
(a) Check the indicator.
(b) Check that the electrolyte level of all the battery cells is between the upper and lower level lines on
the case.
6. BRAKE FLUID LEVEL
(a) Check that the brake fluid levels are near the upper level line on the see-through reservoirs.
7. ENGINE DRIVE BELT
(a) Check the drive belt for fraying, cracks, wear or oiliness.
8. ENGINE OIL LEVEL
(a) Check the level on the dipstick with the engine turned off.
9. POWER STEERING FLUID LEVEL
(a) Check the level on the dipstick.
(b) The level should be in the ºHOTº or ºCOLDº range depending on the fluid temperature.
10. AUTOMATIC TRANSMISSION FLUID LEVEL
(a) Park the vehicle on a level surface.
(b) With the engine idling and the parking brake applied, shift the selector into all the positions from ºPº
to ºLº, and then shift into the ºPº position.
(c) Pull out the dipstick and wipe off the fluid with a clean shop rag. Re-insert the dipstick and check that
the fluid level is in the ºHOTº range.
(d) Perform this check with the fluid at the normal driving temperature (70 to 80°C, 158 to 176°F).
HINT:
Wait until the engine cools down (approx. 30 min.) before checking the fluid level after extended driving at
high speed, in hot weather, in heavy traffic or after pulling a trailer.
11. EXHAUST SYSTEM
(a) Visually inspect for cracks, holes or loose supports.
If any change in the sound of the exhaust or the smell of the exhaust fumes is noticed, locate and correct
the cause.

2005 HIGHLANDER (EWD592U)
18
E GLOSSARY OF TERMS AND SYMBOLS
BATTERY
Stores chemical energy and
converts it into electrical energy.
Provides DC current for the auto's
various electrical circuits.GROUND
The point at which wiring attaches to
the Body, thereby providing a return
path for an electrical circuit; without a
ground, current cannot flow.
CAPACITOR (Condenser)
A small holding unit for temporary
storage of electrical voltage.HEADLIGHTS
Current flow causes a headlight
filament to heat up and emit light. A
headlight may have either a single
(1) filament or a double (2) filament
1. SINGLE
FILAMENT
CIGARETTE LIGHTER
An electric resistance heating
element.2. DOUBLE
FILAMENT
CIRCUIT BREAKER
Basically a reusable fuse, a circuit
breaker will heat and open if too
much current flows through it.
Some units automatically reset when
cool, others must be manually reset.HORN
An electric device which sounds a
loud audible signal.
DIODE
A semiconductor which allows
current flow in only one direction.IGNITION COIL
Converts low-voltage DC current
into high-voltage ignition current for
firing the spark plugs.
DIODE, ZENERA diode which allows current flow in one
direction but blocks reverse flow only up
to a specific voltage. Above that potential,
it passes the excess voltage. This acts as
a simple voltage regulator.LIGHT
Current flow through a filament
causes the filament to heat up and
emit light.
PHOTODIODE
The photodiode is a semiconductor
which controls the current flow
according to the amount of light.LED (LIGHT EMITTING DIODE)
Upon current flow, these diodes emit
light without producing the heat of a
comparable light.
DISTRIBUTOR, IIA
Channels high-voltage current from
the ignition coil to the individual
spark plugs.METER, ANALOG
Current flow activates a magnetic
coil which causes a needle to move,
thereby providing a relative display
against a background calibration.
FUSEA thin metal strip which burns through
when too much current flows through it,
thereby stopping current flow and
protecting a circuit from damage.
FUSIBLE LINK
METER, DIGITAL
Current flow activates one or many
LED's, LCD's, or fluorescent
displays, which provide a relative or
digital display.
FUEL
FUSIBLE LINK
A heavy-gauge wire placed in high
amperage circuits which burns through on
overloads, thereby protecting the circuit.
The numbers indicate the crosssection
surface area of the wires.(for Medium Current Fuse)
(for High Current Fuse or
Fusible Link)MOTOR
A power unit which converts
electrical energy into mechanical
energy, especially rotary motion.
M

2005 HIGHLANDER (EWD592U)
19
E
RELAY
Basically, an electrically operated
switch which may be normally
closed (1) or open (2).
Current flow through a small coil
creates a magnetic field which either
opens or closes an attached switch.
1. NORMALLY
CLOSED
2. NORMALLY
OPEN
SWITCH, MANUAL
Opens and closes
iitth b
SPEAKER
An electromechanical device which
creates sound waves from current
flow.
RELAY, DOUBLE THROW
A relay which passes current
through one set of contacts or the
other.
circuits, thereby
stopping (1) or
allowing (2) current
flow.1. NORMALLY
OPEN
2. NORMALLY
CLOSED
RESISTOR
An electrical component with a fixed
resistance, placed in a circuit to
reduce voltage to a specific value.SWITCH, DOUBLE THROW
A switch which continuously passes
current through one set of contacts
or the other.
RESISTOR, TAPPED
A resistor which supplies two or
more different non adjustable
resistance values.SWITCH, IGNITION
A key operated switch with several
positions which allows various
circuits, particularly the primary
ignition circuit, to become
operational.
RESISTOR, VARIABLE or RHEOSTAT
A controllable resistor with a variable
rate of resistance.
Also called a potentiometer or
rheostat.
SENSOR (Thermistor)
A resistor which varies its resistance
with temperature.SWITCH, WIPER PARK
Automatically returns wipers to the
stop position when the wiper switch
is turned off.
(Reed Switch Type)
SENSOR, SPEED
Uses magnetic impulses to open
and close a switch to create a signal
for activation of other components.TRANSISTOR
A solidstate device typically used as
an electronic relay; stops or passes
current depending on the voltage
applied at ºbaseº.
SHORT PIN
Used to provide an unbroken
connection within a junction block.WIRES
Wires are always drawn as
straight lines on wiring
diagrams.
Crossed wires (1) without a
black dot at the junction are
tj i d
(1) NOT
CONNECTED
SOLENOID
An electromagnetic coil which forms
a magnetic field when current flows,
to move a plunger, etc.
j
not joined;
crossed wires (2) with a
black dot or octagonal ( )
mark at the junction are
spliced (joined)
connections.
(2) SPLICED