radiator cap TOYOTA HIGHLANDER 2001 Service Repair Manual

'05 HIGHLANDER_U (L/O 0409)
336
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
If engine speed does not increase when
the accelerator pedal is depressed, there
may be a problem somewhere in the elec-
tronic throttle control system.
At this time, vibration may occur. Howev-
er, if you depress the accelerator pedal
more firmly and slowly, you can drive your
vehicle at low speeds. Have your vehicle
checked by your Toyota dealer as soon as
possible.
Even if the abnormality of the electronic
throttle control system is corrected during
low speed driving, the system may not be
recovered until the engine is stopped and
the ignition key is turned to ACCº or
LOCKº position.
CAUTION
Be especially careful to prevent erro-
neous pedal operation.
If your engine coolant temperature
gauge indicates overheating, if you ex-
perience a loss of power, or if you hear
a loud knocking or pinging noise, the
engine has probably overheated. You
should follow this procedure...
1. Pull safely off the road, stop the ve-
hicle and turn on your emergency
flashers. Put the transmission in Pº
and apply the parking brake. Turn off
the air conditioning if it is being used.
2. If coolant or steam is boiling out of the
radiator or reservoir, stop the engine.
Wait until the steam subsides before
opening the hood. If there is no coolant
boiling over or steam, leave the engine
running and make sure the electric
cooling fan is operating. If it is not,
turn the ignition off.
CAUTION
To help avoid personal injury, keep
the hood closed until there is no
steam. Escaping steam or coolant is
a sign of very high pressure.
3. Look for obvious coolant leaks from the
radiator, hoses, and under the vehicle.
However, note that water draining from
the air conditioning is normal if it has
been used.
CAUTION
When the engine is running, keep
hands and clothing away from the
moving fan and engine drive belts.
4. If the coolant is leaking, stop the en-
gine immediately. Call a Toyota dealer
for assistance.
5. If there are no obvious leaks, check
the coolant reservoir. If it is dry, add
coolant to the reservoir while the en-
gine is running. Fill it about half full.
For the coolant type, see Coolant type
selectionº on page 383 in Section 7- 2.
CAUTION
Do not attempt to remove the radiator
cap when the engine and radiator are
hot. Serious injury could result from
scalding hot fluid and steam blown
out under pressure.
If you cannot increase engine
speedIf your vehicle overheats

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)

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.

'05 HIGHLANDER_U (L/O 0409)
372
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
1. Engine coolant reservoir
2. Power steering fluid reservoir
3. Engine oil filler cap
4. Engine oil level dipstick
5. Fuse blocks
6. Brake fluid reservoir
7. Battery
8. Radiator
9. Condenser
10. Electric cooling fans
11. Windshield and rear window washer
fluid tank
Engine compartment overview

2AZ- FE engine