manual transmission TOYOTA HIGHLANDER 2001 Service Repair Manual

'05 HIGHLANDER_U (L/O 0409)
321
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

'05 HIGHLANDER_U (L/O 0409)
326
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
TRAILER LIGHTS

Your vehicle is equipped with a wire
harness stored in the rear end under
body. Some models are fitted with a
socket for trailer lights under the rear
bumper. Use either of them to connect
and operate the trailer lights. However,
the trailer lights must comply with fed-
eral, state/provincial and local regula-
tions. See your local recreational ve-
hicle dealer or rental agency for the
correct type of wiring and relays for
your trailer. Check for correct operation
of the turn signals and stop lights each
time you hitch up. Direct splicing may
damage your vehicle's electrical system
and cause a malfunction of your lights.BREAK- IN SCHEDULE

Toyota recommends that you do not
tow a trailer with a new vehicle or a
vehicle with any new power train com-
ponent (engine, transmission, differen-
tial, wheel bearings, etc.) for the first
800 km (500 miles) of driving.
MAINTENANCE

If you tow a trailer, your vehicle will
require more frequent maintenance due
to the additional load. For this informa-
tion, please refer to the scheduled
maintenance information in the Sched-
uled Maintenance Guideº or Owner 's
Manual Supplementº.

Retighten all fixing bolts of the towing
ball and bracket after approximately
1000 km (600 miles) of trailer driving.PRE- TOWING SAFETY CHECK

Check that your vehicle remains level
when a loaded or unloaded trailer is
hitched. Do not drive if the vehicle has
an abnormal nose- up or nose- down
condition, and check for improper
tongue load, overload, worn suspension
or other possible causes.

Make sure the trailer cargo is securely
loaded so that it cannot shift.

Check that your rear view mirrors con-
form to any applicable federal, state/
provincial or local regulations. If not,
install the rear view mirrors required
for towing purposes.
TRAILER TOWING TIPS
When towing a trailer, your vehicle will
handle differently than when not tow-
ing. The three main causes of vehicle-
trailer accidents are driver error, exces-
sive speed and improper trailer loading.
Keep these in mind when towing:

Before starting out, check operation of
the lights and all vehicle- trailer connec-
tions. After driving a short distance,
stop and recheck the lights and con-
nections. Before actually towing a trail-
er, practice turning, stopping and back-
ing with a trailer in an area away from
traffic until you learn the feel.

'05 HIGHLANDER_U (L/O 0409)
409
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
Generally, it is necessary to change
automatic transmission fluid only if your
vehicle is driven under one of the Special
Operating Conditions listed in your
Scheduled Maintenance Guideº or
Owner 's Manual Supplementº. When
changing the automatic transmission fluid,
use only Toyota Genuine ATF Type T- IVº
(ATF JWS3309 or NWS6500) to aid in
assuring optimum transaxle performance.
Notice: Using automatic transmission
fluid other than Toyota Genuine ATF
Type T- IVº may cause deterioration in
shift quality, locking up of your trans-
mission accompanied by vibration, and
ultimately damage the automatic trans-
mission of your vehicle.
Please contact your Toyota dealer for fur-
ther details.
TRANSFER
(four- wheel drive models)
Oil capacity, L (qt., Imp. qt.):
0.9 (1.0, 0.8)
Oil type:
Hypoid gear oil API GL- 5
Recommended oil viscosity:
Above -18
C (0
F)
SAE 90
Below -18
C (0
F)
SAE 80W or 80W- 90REAR DIFFERENTIAL
(four- wheel drive models)
Oil capacity, L (qt., Imp. qt.):
0.9 (1.0, 0.8)
Oil type:
Hypoid gear oil API GL- 5
Recommended oil viscosity:
Above -18
C (0
F)
SAE 90
Below -18
C (0
F)
SAE 80W or 80W- 90
BRAKES
Minimum pedal clearance when depressed
with the force of 490 N (50 kgf, 110 lbf)
with the engine running, mm (in.):
83 (3.3)
Pedal free play, mm (in.):
2Ð3 (0.08Ð0.12)
Pad wear limit, mm (in.):
1.0 (0.04)
Lining wear limit, mm (in.):
1.0 (0.04)
Parking brake adjustment when depressed
with the force of 294 N (30 kgf, 66 lbf):
5Ð7 clicks
Fluid type:
SAE J1703 or FMVSS No.116 DOT 3STEERING
Wheel free play:
Less than 30 mm (1.2 in.)
Power steering fluid type:
Automatic transmission fluid DEXRONII
or III

1 Reset the oil replacement reminder (“MAINT REQD”) light after replacing engine oil, if vehicle is equipped with this light.2 Perform these service items only if you drive primarily under the conditions indicated.3 Required under the terms of the Emission Control Warranty.4 Inspec tthickness measurement and disc runout.5 Ex cept front differential of Corolla Matrix 4WD with manual transmission.6 See page 37 for details.7 Applies t o Coroll a M atrix 4WD and Sienna 4WD.8 Applies to Corolla Matrix 4WD, MR2 Spyder and Sienna 4WD.
Maintenance Log: Cars
30,000 Miles or 36 Months
qReplace engine oil and oil filter1
qRotate tires (except MR2 Spyder)
qReplace cabin air filter (Camry and Camry Solara)
qReplace engine air filter
qReplace spark plugs (ECHO)3
qTighten drive shaft bolt (Corolla and Corolla Matrix)
qInspect the following:__ Ball joints and dust covers
__ Brake lines and hoses
__ Brake linings/drums and brake pads/discs
4
__ Differential oil5
__ Drive shaft boots
__ Engine coolant6
__ Exhaust pipes and mountings
__ Fuel lines and connections, fuel tank band
and fuel tank vapor vent system hoses
Additional Maintenance Items for Special Operating Conditions2
Driving in desert or on dirt roads:
qTighten nuts and bolts on chassis
Driving while towing:
qR epl ac e f ront diff erential oil (all models with manual transmission
e x ce pt Cor oll a M atrix 4WD)
qReplace manual transmission oil
qRepl ac e r ear differential oil8
qRepl ac e t ran sfer case oil7
qTighten nuts and bolts on chassis
Dealer Service Verification:
Date:
M ileage:
7
__ Fuel tank cap gasket
__ Radiator core and condenser
__ Steering gear box
__ Steering linkage and boots
__ Transfer case oil
7
__ Transmission fluid or oil

1 Reset the oil replacement reminder (“MAINT REQD”) light after replacing engine oil, if vehicle is equipped with this light.2 Perform these service items only if you drive primarily under the conditions indicated.3 R equ ir ed under the terms of the Emission Control Warranty.4 Inspect thickness measurement and disc runout.5 Except front differential of Corolla Matrix 4WD with manual transmission.6 Initial inspection at 60,000 miles/72 months. Inspect every 15,000 miles/18 months thereafter.7 See page 37 for details.8 Applies to Corolla Matrix 4WD and Sienna 4WD.9 Applies t o Corolla Matrix 4WD, MR2 Spyder and Sienna 4WD.
Maintenance Log: Cars
60,000 Miles or 72 Months
qReplace engine oil and oil filter1
qRotate tires (except MR2 Spyder)
qReplace cabin air filter (if equipped)
qReplace engine air filter
qReplace spark plugs (ECHO)3
qTighten drive shaft bolt (Corolla and Corolla Matrix)
qInspect the following:__ Ball joints and dust covers
__ B rake lines and hoses
__ Brake linings/drums and brake pads/discs
4
__ Differential oil5
__ Drive belts6
__ Drive shaft boots
__ Engine coolant7
__ Engine valve clearance
__ Exhaust pipes and mountings
Additional Maintenance Items for Special Operating Conditions2
Dr iv ing in desert or on dirt roads:
qTighten nuts and bolts on chassis
Driving while towing:
qReplace front differential oil
qReplace rear differential oil9
qReplace transfer case oil8
qReplace transmission fluid or oil
qTighten nuts and bolts on chassis
Dealer Service Verification:
Date:
M ileage:
11
__ Fuel lines and connections, fuel tank band
and fuel tank vapor vent system hoses
__ Fuel tank cap gasket
__ Radiator core and condenser
__ Steering gear box
__ Steering linkage and boots
__ Transfer case oil
8
__ Transmission fluid or oil

Dealer Service Verification:
Date:
Mileage:
1 Reset the oil replacement reminder (“MAINT REQD”) light after replacing engine oil, if vehicle is equipped with this light.2 Perform these service items only if you drive primarily under the conditions indicated.3 Required under the terms of the Emission Control Warranty.4 Inspec tthic kness measurement and disc runout.5 Ex ce pt front differential of Corolla Matrix 4WD with manual transmission.6 See page 37 for details.7 Applies to Corolla Matrix 4WD and Sienna 4WD.8 Applies to Corolla Matrix 4WD, MR2 Spyder and Sienna 4WD.
Maintenance Log: Cars
90,000 Miles or 108 Months
qReplace engine oil and oil filter1
qRotate tires (except MR2 Spyder)
qReplace cabin air filter (Camry and Camry Solara)
qReplace engine air filter
qReplace spark plugs (ECHO)3
qReplace timing belt (Camry with 1MZFE or 3MZFE, Camry Solara with
3MZFE, Sienna)
qTighten drive shaft bolt (Corolla and Corolla Matrix)
qInspect the following:__ Ball joints and dust covers
__ Brake lines and hoses
__ Brake linings/drums and brake pads/discs
4
__ Differential oil5
__ Drive belts
__ Drive shaft boots
__ Engine coolant
6
__ Exhaust pipes and mountings
Additional Maintenance Items for Special Operating Conditions2
Driving in desert or on dirt roads:
qTighten nuts and bolts on chassis
Driving while towing:
qReplace front differential oil (all models with manual transmission
except Corolla Matrix 4WD)
qReplace manual transmission oil
qReplace rear differential oil8
qReplace transfer case oil7
qTighten nuts and bolts on chassis
Dealer Service Verification:
Date:
M ileage:
__ Fuel lines and connections, fuel tank band
and fuel tank vapor vent system hoses
__ Fuel tank cap gasket
__ Radiator core and condenser
__ Steering gear box
__ Steering linkage and boots
__ Transfer case oil
7
__ Tran smis sion flu id oroil
15

1 Reset the oil replacement reminder (“MAINT REQD”) light after replacing engine oil, if vehicle is equipped with this light.2 Per form these service items only if you drive primarily under the conditions indicated.3 Required under the terms of the Emission Control Warranty. Does not apply to Camry PZEV with 2AZFE in California,
New York, Massachusetts, Maine and Vermont. For this model, replacement interval is 150,000 miles.
4 Inspect thickness measurement and disc runout.5 Except front differential of Corolla Matrix 4WD with manual transmission.6 See page 37 for details.7 Applies to Corolla Matrix 4WD and Sienna 4WD.8 Applies to Corolla Matrix 4WD, MR2 Spyder and Sienna 4WD.
Maintenance Log: Cars
120,000 Miles or 144 Months
qReplace engine oil and oil filter1
qRotate tires (except MR2 Spyder)
qReplace cabin air filter (if equipped)
qReplace engine air filter
qReplace spark plugs3
qTighten drive shaft bolt (Corolla and Corolla Matrix)
qInspect the following:__ B all joints and dust covers
__ Brake lines and hoses
__ Brake linings/drums and brake pads/discs
4
__ Diff erential oil5
__ Drive belts
__ Drive shaft boots
__ Engine coolant
6
__ Engine valve clearance
__ Exhaust pipes and mountings
Additional Maintenance Items for Special Operating Conditions2
Driving in desert or on dirt roads:
qTighten nuts and bolts on chassis
Driving while towing:
qReplace front differential oil
qReplace rear differential oil8
qReplace transfer case oil7
qReplace transmission fluid or oil
qTighten nuts and bolts on chassis
Dealer Service Verification:
Date:
Mileage:
19
__ Fuel lines and connections, fuel tank band
and fuel tank vapor vent system hoses
__ Fuel tank cap gasket
__ Radiator core and condenser
__ Steering gear box
__ St eering linkage and boots
__ Transfer case oil
7
__ Transmission fluid or oil

Maintenance Log: SUVs and Trucks
6Applies to Tacoma with 1GRFE, Tundra with 1GRFE and 4Runner with 1GRFE. Required under the terms of the Emission Control Warranty.
7Inspect thickness measurement and disc runout.8See p age 37 f or details.
30,000 Miles or 36 Months
qReplace engine oil and oil filter1qReplace engine air filter
qRotate tiresqReplace cabin air filter (if equipped)
qLubricate drive shaft bushing (Land Cruiser)
qLubricate propeller shaft4
qLubricate wheel bearings (Land Cruiser)
qReplace limitedslip differential oil, if equipped5
qReplace spark plugs6
qRetorque drive shaft bolt (4WD RAV4)
qRetorque propeller shaft bolt (all models except Highlander and RAV4)
qInspect the following:__ Automatic transmission fluid
__ Ball joints and dust covers
__ Brake lines and hoses
__ Brake linings/drums and brake pads/discs
7
__ Drive shaft boots3
__ Engine coolant8
__ Exhaust pipes and mountings
__ Front differential oil (4WD models, Highlander and RAV4)
__ Fuel lines and connections, fuel tank band and f uel tankvapor vent system hoses
Additional Maintenance Items for Special Operating Conditions2
Driving in desert or on dirt roads:
qTighten nuts and bolts on chassis
Dr iv in g while towing:
qReplace front differential oil (2WD RAV4 with manual transmission, all 4WD models
except RAV4 with automatic transmission and Highlander)
qReplace manual transmission oil (RAV4, Tundra)
qReplace rear differential oil, including limitedslip (all models except 2WD
Highlander and 2WD RAV4)
qReplace transfer case oil (4WD models)
qTighten nuts and bolts on chassis
Dealer Service Verification:
Date:
Mileage:
23
__ F uel tank cap gasket
__ Manual transmission oil (RAV4, Tundra)
__ Radiator core and condenser
__ Rear differential oil (all models except 2WD Highlander and 2WD RAV4)
__ St eering gear box
__ Steering linkage and boots
__ Transfer case oil (all 4WD models)

Maintenance Log: SUVs and Trucks
7 Inspect thickness measurement and disc runout.8 Applies to Land C ru iser, Sequoia, Tundra and 4Runner with 2UZFE. Required only for vehicles in California,
Massachusetts and New York.
9 Init ial i nspec tion at 60,000 miles/72 months. Inspect every 15,000 miles/18 months thereafter.10See p age 37 for details.
60,000 Miles or 72 Months
qReplace engine oil and oil filter1qReplace engine air filter
qRotate tiresqReplace cabin air filter (if equipped)
qLubricate drive shaft bushing (Land Cruiser)
qLubricate propeller shaft4
qLubricate wheel bearings (Land Cruiser)
qReplace limitedslip differential oil, if equipped5
qReplace spark plugs6
qRetorque drive shaft bolt (4WD RAV4)
qRetorque propeller shaft bolt (all models except Highlander and RAV4)
qInspect the following:__ Automatic transmission fluid
__ Ball joints and dust covers
__ Brake lines and hoses
__ Brake linings/drums and brake pads/discs
7
__ Charcoal canister8
__ Dr ive belts9
__ Drive shaft boots3
__ Engine coolant10
__ E ngine valv e clearance (except Tacoma
with 2TRFE)
__ Front differential oil (4WD models, Highlander, RAV4)
Add ition al Maintenance Items for Special Operating Conditions2
Driving in desert or on dirt roads:
qTighten nuts and bolts on chassis
Driving while towing:
qReplace automatic transmission fluid
qRepl ac e f ront diff erential oil (Highlander, RAV4 and all 4WD models)
qReplace manual transmission oil (RAV4, Tundra)
qRepl ac e rear differential oil, including limited slip (all models except 2WD
Hi gh land erand 2WD RA V4)
qReplace transfer case oil (4WD models)
qTigh ten nuts and bolts on chassis
Dea ler Service Verification:
D at e :
Mileage:
27
__ Exhaust pipes and mountings
__ Fuel lines and connections, fuel tank band and f uel tank vapor vent system hoses
__ Fuel tank cap gasket
__ Manual transmission oil (RAV4, Tundra)
__ Radiator core and condenser
__ Rear differential oil (all models except
2WD Highlander and 2WD RAV4)
__ Steering gear box
__ Steer ing linkage and boots
__ Transfer case oil (all 4WD models)

5,000Mile Maintenance Intervals
7,500Mile Maintenance IntervalsTo determine the appropriate maintenance
interval for your vehicle, see page 16.
Dealer Service Verification:
Date:
Mileage:
Dea ler Service Verification:
Maintenance Log: SUVs and Trucks
6Applies to Tacoma with 1GRFE, Tundra with 1GRFE and 4Runner with 1GRFE. Required under the terms of the
Emission Control Warranty.
7 Applies to Highlander with 3MZFE, Land Cruiser, Sequoia, Tundra with 2UZFE and 4Runner with 2UZFE.8Inspect thickness measurement and disc runout.9See p age 37 f or details.
90,000 Miles or 108 Months
qReplace engine oil and oil filter1qReplace engine air filter
qRotate tiresqReplace cabin air filter (if equipped)
qLubricate drive shaft bushing (Land Cruiser)
qLubricate propeller shaft4
qLubricate wheel bearings (Land Cruiser)
qReplace limitedslip differential oil, if equipped5
qReplace spark plugs6
qReplace timing belt7
qRetorque drive shaft bolt (4WD RAV4)
qRetorque propeller shaft bolt (all models except Highlander and RAV4)
qInspect the following:__ Automatic transmission fluid
__ Ball joints and dust covers
__ Brake lines and hoses
__ Brake linings/drums and brake pads/discs
8
__ Drive belts
__ Drive shaft boots3
__ Engine coolant9
__ Ex haust pipes and mountings
__ Front differential oil (4WD models, Highlander and RAV4)
Additional Maintenance Items for Special Operating Conditions2
Driving in desert or on dirt roads:
qTighten nuts and bolts on chassis
Driving while towing:
qRepl ace front differential oil (2WD RAV4 with manual transmission, all 4WD models
e x cept RAV4 with automatic transmission and Highlander)
qR eplace manual transmission oil (RAV4, Tundra)
qReplace rear differential oil, including limited slip (all models except 2WD
Hi ghlander and 2WD RAV4)
qR epl ac e t ran sfer ca se oil (4WD models)
qTighten nuts and bolts on chassis
Dea ler Service Verification:
D at e :
Mileage:
31
__ Fuel lines and connections, fuel tank band and fuel tank vapor vent system hoses
__ Fuel tank cap gasket
__ Manual transmission oil (RAV4, Tundra)
__ Radiator core and condenser
__ Rear differential oil (all models except 2WD Highlander and 2WD RAV4)
__ Steering gear box
__ St eering linkage and boots
__ Transfer case oil (all 4WD models)