air suspension TOYOTA HIGHLANDER 2001 Service Repair Manual

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2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)

In a rollover crash, an unbelted per-
son is significantly more likely to
die than a person wearing a seat
belt. Therefore, the driver and all
passengers should fasten their seat
belts whenever the vehicle is mo-
ving.

When driving off- road or in rugged
terrain, do not drive at excessive
speeds, jump, make sharp turns,
strike objects, etc. This may cause
loss of control or vehicle rollover
causing death or serious injury. You
are also risking expensive damage
to your vehicle's suspension and
chassis.
NOTICE

If driving through water, such as
when crossing shallow streams,
first check the depth of the water
and the bottom of the river bed for
firmness. Drive slowly and avoid
deep water.

Take all necessary safety measures
to ensure that water damage to the
engine or other components does
not occur.
Water entering the engine air intake
will cause severe engine damage.
Water can wash the grease from
wheel bearings, causing rusting and
premature failure, and may also en-
ter the differentials, transmission
and transfer case, reducing the gear
oil's lubricating qualities.

Sand and mud that has accumulated
in brake drums and around brake
discs may affect braking efficiency
and may damage brake system com-
ponents.

Always perform a maintenance in-
spection after each day of off- road
driving that has taken you through
rough terrain, sand, mud, or water.
For scheduled maintenance informa-
tion, refer to the Scheduled Main-
tenance Guideº or Owner's Manual
Supplementº.
Make sure your coolant is properly pro-
tected against freezing.
Only use Toyota Super Long Life Coolantº
or similar high quality ethylene glycol
based non- silicate, non- amine, non- nitrite,
and non- borate coolant with long- life
hybrid organic acid technology. (Coolant
with long- life hybrid organic acid
technology is a combination of low
phosphates and organic acids.)
See Checking the engine coolant levelº
on page 383 in Section 7- 2 for details of
coolant type selection.
For the U.S.A.ÐToyota Super Long Life
Coolantº is a mixture of 50% coolant and
50% deionized water. This coolant pro-
vides protection down to about -35C
(- 31F).
For CanadaÐToyota Super Long Life
Coolantº is a mixture of 55% coolant and
45% deionized water. This coolant pro-
vides protection down to about -42C
(- 44F).
NOTICE
Do not use plain water alone.
Winter driving tips

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Tire inflation pressure
Check the pressure with a gauge ev-
ery two weeks, or at least once a
month. See page 385 in Section 7- 2
for additional information.
Tire surface and wheel nuts
Check the tires carefully for cuts,
damage or excessive wear. See page
388 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
Guideº or Owner 's Manual Supple-
mentº.) See page 390 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 normalIf 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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The seat belt pretensioner system con-
sists mainly of the following components
and their locations are shown in the il-
lustration.
1. Front airbag sensors
2. SRS warning light
3. Front passenger occupant classification
system (ECU and sensors)
4. Seat belt pretensioner assemblies
5. Front passenger 's seat belt buckle
switch
6. Airbag sensor assemblyThe seat belt pretensioners are controlled
by the airbag sensor assembly. The airbag
sensor assembly consists of a safing sen-
sor and airbag sensor.
When the seat belt pretensioners are acti-
vated, an operating noise may be heard
and a small amount of non- toxic gas may
be released. This does not indicate that
a fire is occurring. This gas is normally
harmless.
Once the seat belt pretensioners have
been activated, the seat belt retractors
remain locked.CAUTION
Do not modify, remove, strike or open
the seat belt pretensioner assemblies,
airbag sensor or surrounding area or
wiring. Failure to follow these instruc-
tions may prevent the seat belt pre-
tensioners from activating correctly,
cause sudden operation of the system
or disable the system, which could
result in death or serious injury. Con-
sult your Toyota dealer about any re-
pair and modification.
NOTICE
Do not perform any of the following
changes without consulting your
Toyota dealer. Such changes can
interfere with proper operation of the
seat belt pretensioners in some
cases.

Installation of electronic devices
such as a mobile two- way radio,
cassette tape player or compact
disc player

Repairs on or near the front seat
belt retractor assemblies

Modification of the suspension sys-
tem

Modification of the front end struc-
ture

Attachment of a grille guard (bull
bar, kangaroo bar, etc.), snowplow,
winches or any other equipment to
the front end

Repairs made on or near the front
fenders, front end structure or con-
sole

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2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
NOTICE
Do not perform any of the following
changes without consulting your
Toyota dealer. Such changes can
interfere with proper operation of the
SRS front airbag system in some
cases.

Installation of electronic devices
such as a mobile two- way radio,
cassette tape player or compact
disc player

Modification of the suspension sys-
tem

Modification of the front end struc-
ture

Attachment of a grille guard (bull
bar, kangaroo bar, etc.), snowplow,
winches or any other equipment to
the front end

Repairs made on or near the front
fenders, front end structure, con-
sole, steering column, steering
wheel or dashboard near the front
passenger airbag
This indicator comes on when the igni-
tion key is turned to the ONº position.
It goes off after about 6 seconds. This
means the SRS front airbags are oper-
ating properly.This warning light system monitors the
airbag sensor assembly, front airbag sen-
sors, side and curtain shield airbag sen-
sors, curtain shield airbag sensors, driv-
er 's seat position sensor, driver 's seat belt
buckle switch, front passenger occupant
classification system, AIRBAG ONº indi-
cator light, AIRBAG OFFº indicator light,
front passenger 's seat belt buckle switch,
seat belt pretensioner assemblies, inflat-
ors, warning light, interconnecting wiring
and power sources. (For details, see Ser-
vice reminder indicators and warning buzz-
ersº on page 135 in Section 1- 6.)
If either of the following conditions occurs,
this indicates a malfunction of the airbags
or seat belt pretensioners. Contact your
Toyota dealer as soon as possible.

The light does not come on when the
ignition key is turned to the ONº posi-
tion or remains on for more than 6
seconds or flashes.

The light comes on or starts flashing
while driving.

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Do not hook a hanger, heavy or
sharp pointed objects on the coat
hook. If the curtain shield airbag
inflates, those items will be thrown
away with great force or the curtain
shield airbag may not activate cor-
rectly, resulting in death or serious
injury. When you hang clothes,
hang them on the coat hook direct-
ly.

Do not use seat accessories which
cover the parts where the side air-
bags inflate. Such accessories may
prevent the side airbags from acti-
vating correctly, causing death or
serious injury.

Do not modify or replace the seats
or upholstery of the seats with side
airbags. Such changes may prevent
the side airbag system from activat-
ing correctly, disable the system or
cause the side airbags to inflate ac-
cidentally, resulting in death or seri-
ous injury.

Do not disassemble or repair the
front and rear pillars and roof side
rails containing the curtain shield
airbags. Such changes may disable
the system or cause the curtain
shield airbags to inflate accidental-
ly, resulting in death or serious in-
jury.
Failure to follow these instructions
can result in death or serious injury.
Consult your Toyota dealer about any
repair and modification.
If you wish to modify your vehicle for
a person with a physical disability,
consult your Toyota dealer. It may
dangerously interfere with the SRS
side airbags and curtain shield air-
bags operation.NOTICE
Do not perform any of the following
changes without consulting your
Toyota dealer. Such changes can
interfere with proper operation of the
SRS side airbag and curtain shield
airbag system in some cases.

Installation of electronic devices
such as a mobile two- way radio,
cassette tape player or compact
disc player

Modification of the suspension sys-
tem

Modification of the side structure of
the passenger compartment

Repairs made on or near the con-
sole or front seat

Explanation of Maintenance Items
36
The following descriptions are provided to give you a better understanding of
the maintenance items that should be performed on your vehicle. The scheduled
maintenance log indicates at which mileage/time intervals each item should be
performed. Please note that many maintenance items should be performed only
by a qualified technician.
For further information on maintenance items you can perform yourself,
see the “Vehicle Maintenance and Care” and “DoItYourself Maintenance”
sections of your
Owner’s Manual.
Automatic Transmission Fluid or Manual Transmission Oil
Inspect or replace at specified intervals. When performing inspections, check each
component for signs of leakage. If you discover any leakage, have it repaired by a
qualified technician immediately.
Ball Joints and Dust Covers
Check the suspension and steering linkage ball joints for looseness and damage.
Check all dust covers for deterioration and damage. Replace any deteriorated ordamaged parts. Aqualified technician should perform these operations.
Brake Lines and Hoses
Visually inspect for proper installation. Check for chafing, cracks, deterioration
and signs of leakage. Replace any deteriorated or damaged parts. A qualified
technician should perform these operations.
Brake Linings/Drums and Brake Pads/Discs
Check the brake linings (shoes) and drums for scoring, burning, fluid leakage,
broken parts and excessive wear. Check the pads for excessive wear and the
discs for runout, excessive wear and fluid leakage. Replace any deteriorated ordamaged parts. A qualified technician should perform these operations.
Cabin Air Filter
Replace at specified intervals. Driving in heavy traffic, on dirt roads or in urban,
desert or dusty areas may shorten filter’s life. More frequent replacement may
be necessary.
Charcoal Canister (CA, MA and NY vehicles)
Check for internal damage and clogging. If necessary, clean with compressed air
or replace. A qualified technician should perform these operations.

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.