TOYOTA HIGHLANDER 2001 Service Repair Manual

D25518
* 2WD:
1,080 mm (42.52 in.)
4WD:
1,110 mm (43.70 in.) ...
: CENTER OF VEHICLE
GRAVITY (unload condition) Rubber Attachment*L Center of Lift
Center of Wheel
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
4. NOTICE FOR USING SWING ARM TYPE LIFT
(a) Follow safety procedures outlined in its instruction manual.
(b) Use a swing arm equipped with a rubber attachment, as shown in the illustration.
(c) When using the lift, its center should be as close to the vehicle's center of gravity as possible.
(d) Set the vehicle on the lift as level as possible. Then match the groove of the cradle to the rigid rack
support location.
(e) Be sure to lock the swing arms before lifting and during work (if equipped with arm locks).
(f) Lift the vehicle up off the ground. Stand at a safe distance and shake the vehicle to check its stability.

D25522
85 mm (3.35 in.)
70 mm (2.76 in.)
200 mm (7.87 in.) 100 mm (3.94 in.) Attachment DimensionsB
AC 01-24
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5. NOTICE FOR USING PLATE TYPE LIFT
(a) Follow safety procedures outlined in its instruction manual.
(b) Use plate lift attachments (rubber lifting blocks) on top of the plate surface.
(c) Refer to the table below to determine how to properly set the vehicle.
Right and left set positionPlace the vehicle over the center of the lift.
Front and rear set position
Place the attachments at the ends of the rubber plate surface, under the vehicle lift pad (A and C in the illustra-
tion). Raise the plate slightly and reposition the vehicle so the top of the attachment (B in the illustration) is
aligned with the front side notch in the vehicle rocker flange.
(d) Lift the vehicle up off the ground, and shake it to make sure that it is stable.

i
2005 HIGHLANDER Navigation from Aug. '04 Prod. (OM48539U)
Introduction
Thank you for your purchase of the Navigation System. Please read this manual carefully to ensure proper use. Keep this manual
in your vehicle at all times.
The Navigation System is one of the most technologically advanced vehicle accessories ever developed. The system receives satellite signals
from the Global Positioning System (GPS) operated by the U.S. Department of Defense. Using these signals and other vehicle sensors, the
system indicates your present position and assists in locating a desired destination.
The navigation system is designed to select efficient routes from your present starting location to your destination. The system is designed
to direct you to a destination that is unfamiliar to you in an efficient manner. The system uses the maps of DENSO. The calculated routes
may not be the shortest nor the least traffic congested. Your own personal local knowledge or short cutº may at times be faster than the calcu-
lated routes.
The navigation system's database includes about 75 Point of Interest categories to allow you to easily select destinations such as restaurants
and banks. If a destination is not in the database, you can enter the street address or a major intersection close to it and the system will guide
you there. The system will provide both a visual map and audio instructions. The audio instructions will announce the distance remaining
and the direction to turn in approaching a fork or intersection. These voice instructions will help you keep your eyes on the road and are timed
to provide enough time to allow you to maneuver, change lanes or slow down.
Please be aware that all current vehicle navigation systems have certain limitations that may affect their ability to perform properly.
The accuracy of the vehicle's position depends on the satellite condition, road configuration, vehicle condition or other circumstan-
ces. For more information on the limitations of the system, refer to pages 9 through 11.

2005 HIGHLANDER (EWD592U)
2
A INTRODUCTION
This manual consists of the following 13 sections:
No.
SectionDescription
A
INDEXIndex of the contents of this manual.
A
INTRODUCTIONBrief explanation of each section.
BHOW TO USE THIS
MANUALInstructions on how to use this manual.
CTROUBLE-
SHOOTINGDescribes the basic inspection procedures for electrical circuits.
DABBREVIATIONSDefines the abbreviations used in this manual.
E
GLOSSARY OF
TERMS AND
SYMBOLS
Defines the symbols and functions of major parts.
FRELAY LOCATIONSShows position of the Electronic Control Unit, Relays, Relay Block, etc.
This section is closely related to the system circuit.
GELECTRICAL
WIRING ROUTINGDescribes position of Parts Connectors, Splice points, Ground points, etc.
This section is closely related to the system circuit.
INDEXIndex of the system circuits.
H
SYSTEM CIRCUITS
Electrical circuits of each system are shown from the power supply through ground
points. Wiring connections and their positions are shown and classified by code
according to the connection method. (Refer to the section, ºHow to use this manualº).
The ºSystem Outlineº and ºService Hintsº useful for troubleshooting are also contained
in this section.
IGROUND POINTShows ground positions of all parts described in this manual.
JPOWER SOURCE
(Current Flow Chart)Describes power distribution from the power supply to various electrical loads.
KCONNECTOR LISTDescribes the form of the connectors for the parts appeared in this book.
This section is closely related to the system circuit.
LPART NUMBER OF
CONNECTORSIndicates the part number of the connectors used in this manual.
M
OVERALL
ELECTRICAL
WIRING DIAGRAM
Provides circuit diagrams showing the circuit connections.

010QJ-02
12
3
4 6
5
D25016
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REPAIR INSTRUCTION
PRECAUTION
(b) HINTS ON OPERATIONS
1Looks
Always wear a clean uniform.

Hat and safety shoes must be worn.
2Vehicle protection
Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation.
3Safe operation

When working with 2 or more persons, be sure to check safety for one another.

When working with the engine running, pay attention to providing ventilation for exhaust fumes in the
workshop.

If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety
equipment and take extra care not to injure yourself or others.

When jacking up the vehicle, be sure to support the specified location with a safety stand.

When lifting up the vehicle, use appropriate safety equipment.
4Preparation of tools and
measuring gauge
Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement.
5
Removal and installation,
disassembly and assem-
bly operations

Diagnose with a thorough understanding of proper procedures and of the reported problem.

Before removing the parts, check the general condition of the assembly and for deformation and damage.

When the assembly is complicated, take notes. For example, note the total number of electrical connections,
bolts, or hoses removed. Add matchmarks to insure re-assembly of components in the original positions.
Temporarily mark hoses and their fittings, if needed.

Clean and wash the removed parts if necessary and assemble them after a thorough check.
6Removed parts

Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the
new parts.

As for non-reusable parts such as a gasket, an O-ring, and a self-locking nut, replace them with new ones
following the instructions in this manual.

Retain the removed parts for customer inspection, if requested.

Z11554
Seal Lock Adhesive
BE1367
Medium Current Fuse and High Current
Fuse Equal Amperage Rating
D27353D27353D27353
V35002
Illustration
Symbol Part NameAbbreviation
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSEFUSE
M-FUSE
H-FUSE 01-6
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) JACKING UP AND SUPPORTING VEHICLE
(1) Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the
vehicle at the proper locations (see page 01-21).
(d) PRECOATED PARTS
(1) Precoated parts are bolts and nuts, that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
moved in anyway, it must be recoated with the spe-
cified adhesive.
(3) When reusing precoated parts, clean off the old
adhesive and dry the part with compressed air.
Then apply new seal lock adhesive appropriate to
the bolts and nut.
NOTICE:
Perform the torque with the lower limit value of the torque
tolerance.
(4) Some seal lock agents harden slowly. You may
have to wait for the seal lock agent to harden.
(e) GASKETS
(1) When necessary, use a sealer on gaskets to prevent leaks.
(f) BOLTS, NUTS AND SCREWS
(1) Carefully follow all the specifications for tightening torques. Always use a torque wrench.
(g) FUSES
(1) When replacing fuses, be sure that the new fuse
has the correct amperage rating. DO NOT exceed
the rating or use one with a lower rating.

D25786
Shape (Example)Removal/Installation
Clip Remover
Pliers
Screwdriver
Scraper
Protective Tape
Clip



Protective Tape
Remove clips from front or rear using clip remover
or pliers.
Remove fasteners with a clip remover or screwdriver.
Remove clips with a wide scraper to prevent
panel damage.
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(h) CLIPS
(1) The removal and installation methods of typical clips used in body parts are shown in the table
below.
HINT:
If clips are damaged during a procedure, always replace the damaged clip with a new clip.

V35006
Shape (Example)Removal/Installation
Removal Installation
Removal Installation
Removal InstallationScrewdriver
Screwdriver
ScrewdriverClip Remover
Clip Remover
Clip Remover
Push
Push
Push
Small Clip Remover
Remove rivet by pushing the center pin through and prying
out the rivet shell.
Remove rivet by unscrewing the center pin and prying out
the rivet shell.
Remove rivet by prying out the pin and then prying out the
rivet shell. 01-8
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D31750
CORRECT
INCORRECT
D25064
L1 L2L1 L2L1 L2L1 L2L1 L2
D02612
L2 L1L2 L1L2 L1L2 L1L2 L1
D01201
- INTRODUCTIONREPAIR INSTRUCTION
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(i) REMOVAL AND INSTALLATION OF VACUUM HOSES
(1) To disconnect vacuum hoses, pull and twist from
the end of the hose. Do not pull from the middle of
the hose as this may cause damage.
(2) When disconnecting vacuum hoses, use tags to
identify where they should be reconnected.
(3) After completing the job, double check that the vac-
uum hoses are properly connected. The label under
the hood shows the proper layout.
(4) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step-down
adapter for adjustment. Once the hose has been
stretched, it may leak air.
(j) TORQUE WHEN USING TORQUE WRENCH WITH EX-
TENSION TOOL
(1) If SST or an extension tool is combined with the
torque wrench to extend its length, do not tighten
the torque wrench to the specified torque values in
this manual. The resulting torque will be excessive.
(2) Use the formula below to calculate special torque
values for situations where SST or an extension tool
is combined with the torque wrench.
(3) Formula: T' = T x L2/(L1 + L2)
T'Reading of torque wrench {NVm (kgfVcm, ftVlbf)}
TTorque {NVm (kgfVcm, ftVlbf)}
L1Length of SST or extension tool (cm)
L2Length of torque wrench (cm)

01-10
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1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
HINT:
The HIGHLANDER is equipped with a Supplemental Restraint System (SRS) and seat belt pretensioner.
Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly
deploy during servicing and lead to serious injury.
Furthermore, if a mistake is made when servicing the SRS, it is possible that the SRS may fail to operate
properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to
read the following section carefully.
(a) GENERAL NOTICE
(1) Malfunction symptoms of the SRS are difficult to confirm so the Diagnostic Trouble Codes (DTCs)
become the most important source of information when troubleshooting. When troubleshooting
the SRS, always check the DTCs before disconnecting the battery (see page 05-1215).
(2) To avoid serious injury, servicing the SRS must be started at least 90 seconds after:

The ignition switch is turned to the LOCK position.

The negative (-) terminal cable is disconnected from the battery.
(The SRS is equipped with a back-up power source. If work is started within 90 seconds of dis-
connecting the negative (-) terminal cable from the battery, the SRS may deploy.)
Disconnecting the negative (-) terminal cable will erase the memory of all vehicle systems. Initial-
ize the systems after disconnecting/reconnecting the cable.
CAUTION:
Never use a back-up power source (battery or other) in an attempt to avoid erasing system memory.
The back-up power source inadvertently may inadvertently power the SRS and cause it to deploy.
(3) In minor collisions where the SRS does not deploy, the horn button assembly, instrument panel
passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly and seat
belt pretensioner should be inspected before further use of the vehicle (see pages 60-19,
60-31, 60-40, 60-46, and 61-8).
(4) Never use SRS parts from another vehicle. When replacing parts, use new parts.
(5) Before repairs, remove the airbag sensor if impacts are likely to be applied to the sensor during
repairs.
(6) Never disassemble and repair the airbag sensor assembly, horn button assembly, instrument
panel passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly
or seat belt pretensioner.
(7) Replace the center airbag sensor assembly, side airbag sensor assembly, horn button assembly
or the instrument panel passenger airbag assembly, front seat airbag assembly or curtain shield
airbag assembly if: 1) damage has occurred from being dropped, or 2) cracks, dents or other
defects in the case, bracket or connector are present.
(8) Do not directly expose the airbag sensor assembly, the horn button assembly, the instrument
panel passenger airbag assembly, front seat airbag assembly, the curtain shield airbag assem-
bly or the seat belt pretensioner to hot air or flames.
(9) Use a voltmeter/ohmmeter with high impedance (10 kW/V minimum) for troubleshooting electri-
cal circuits.
(10) Information labels are attached to the SRS components. Follow the instructions on the labels.
(11) After work on the SRS is completed, check the SRS warning light (see page 05-1207).