wheel torque TOYOTA HIGHLANDER 2001 Service Repair Manual

'05 HIGHLANDER_U (L/O 0409)
347
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
Tighten each nut a little at a time in
the order shown. Repeat the process
until all the nuts are tight.
CAUTION

When lowering the vehicle,
make sure all portions of your
body and all other persons
around will not be injured as
the vehicle is lowered to the
ground.

Have the wheel nuts tightened
with torque wrench to 103 N´m
(10.5 kgf´m, 76 ft´lbf), as soon
as possible after changing
wheels. Otherwise, the nuts
may loosen and the wheels
may fall off, which could cause
a serious accident.
Ty p e A
Ty p e B10.Reinstall the wheel ornament.
1. Put the wheel ornament into posi-
tion.
2. Then tap it firmly with the side or
heel of your hand to snap it into
place.
CAUTION
Take due care in handling the or-
nament to avoid unexpected per-
sonal injury.
ÐReinstalling wheel ornament

'05 HIGHLANDER_U (L/O 0409)
348
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
11. Check the air pressure of the re-
placed tire.
Adjust the air pressure to the specifi-
cation designated on page 410 in
Section 8. If the pressure is lower,
drive slowly to the nearest service
station and fill to the correct pressure.
Do not forget to reinstall the tire infla-
tion valve cap as dirt and moisture
could get into the valve core and
possibly cause air leakage. If the cap
is missing, have a new one put on as
soon as possible.
12.Restow all the tools, jack and
flat tire securely.
As soon after changing wheels as
possible, tighten the wheel nuts to the
torque specified on page 410 in Sec-
tion 8 with a torque wrench. Have a
technician repair the flat tire and re-
place the spare tire with it.
Initial adjustment of the tire pres-
sure warning system is necessary
after you have replaced your tires
or wheels. See Tire pressure
warning systemº on page 161 in
Section 1- 7.CAUTION
Before driving, make sure all the
tools, jack and flat tire are se-
curely in place in their storage
location to reduce the possibility
of personal injury during a colli-
sion or sudden braking.
If your vehicle becomes stuck in snow,
mud, sand, etc., then you may attempt
to rock the vehicle free by moving it
forward and backward.
Two- wheel drive modelsÐ
Turn off the traction control system to
become unstuck to allow the tires to
spin enough to remove the vehicle from
the obstruction. (For details, see Trac-
tion control system (two- wheel drive
models)º on page 156 in Section 1- 7.)
CAUTION
Do not attempt to rock the vehicle
free by moving it forward and back-
ward if people or objects are any-
where near the vehicle. During the
rocking operation the vehicle may
suddenly move forward or backward
as it becomes unstuck, causing injury
or damage to nearby people or ob-
jects.
ÐAfter changing wheels If your vehicle becomes stuck

'05 HIGHLANDER_U (L/O 0409)
410
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
Engine compartment
Tires
Ti r e siz eTi r e inf lat ion pr es s ur e
Front Rear
P225/70R16 101S
225/65R17 101S210 (2.1, 30) 210 (2.1, 30)
210 (2.1, 30) 210 (2.1, 30)Wheel size
16
6 1/2 JJ
17
6 1/ 2 JJ
When driving under the above load condition at sustained high speeds above
160 km/h (100 mph), in countries where such speeds are permitted by- low,
inflate the front and rear tires to the following tire inflation pressure provided
that it does not exceed the maximum cold tire inflation pressure molded
on the tire sidewall.
P225/70R16 101S tires 240 kPa (2.4 kgf/cm
2
or bar, 35 psi)
225/65R17 101S tires 230 kPa (2.3 kgf/cm2
or bar, 33 psi)
Wheel nut torque, N
´m (kgf´m, ft´lbf):
103 (10.5, 76)
NOTE: For a complete information on tires (e.g. replacing tires or replacing
wheels), see Checking tire inflation pressureº through Aluminum
wheel precautionsº, pages 385 through 393, in Section 7- 2. Tire size and cold tire inflation pressure:
kPa (kgf/cm
2
or bar, psi)
Fuses

2005 HIGHLANDER (EWD592U)
184
VSC and Tire Pressure Warning System
1. ABS Operation
If the brake pedal is depressed suddenly, the ABS controls the hydraulic pressure of the wheel cylinders for all the four
wheels to automatically avoid wheel locking and ensure the directional and steering stability of the vehicle. If the brake pedal
is depressed suddenly, the skid control ECU with actuator controls the solenoids in the actuators using the signals from the
sensors to move the brake fluid to the reservoir in order to release the braking pressure applied to the wheel cylinder. If the
skid control ECU with actuator detects that the fluid pressure in the wheel cylinder is insufficient, the ECU controls the
solenoids in the actuators to increase the braking pressure.
2. Traction Control Operation
The traction control system controls the engine torque, the hydraulic pressure of the driving wheel cylinders, slipping of the
wheels which may occur at start or acceleration of the vehicle, to ensure an optimal driving power and vehicle stability
corresponding to the road conditions.
3. VSC Operation
Unexpected road conditions, vehicle speed, emergency situation, and any other external factors may cause large under- or
over-steering of the vehicle. If this occurs, the VSC system automatically controls the engine power and wheel brakes to
reduce the under- or over-steering.
To reduce large over-steering :
If the VSC system determines that the over-steering is large, it activates the brakes for the outer front turning wheels
depending on the degree of the over-steering to produce the moment toward the outside of the vehicle and reduce the
over-steering.
To reduce large under-steering :
If the VSC system determines that the under-steering is large, it controls the engine power and activates the rear wheel
brakes to reduce the under-steering.
VSC indicator light
If an mulfunction occurs in the VSC system, the VSC indicator lights up to warn the driver.
4. Mutual System Control
To efficiently operate the VSC system at its optimal level, the VSC system and other control systems are mutually controlled
while the VSC system is being operated.
Engine control
The engine power does not interfere with the VSC brake control by fuel cut controlling and reducing the engine output.
Engine control and electronically controlled transmission control
The strong braking force does not interfere with the braking force control of the VSC system by turning off the accel and
reducing changes in the driving torque at shift-down.
VSC system operation indication
The slip indicator light flashes and the buzzer alarm intermittently to warn the driver that the current road is slippery, while the
VSC system is being operated.
5. Fail Safe Function
If an mulfunction occurs in the skid control ECU with actuator, sensor signals, and/or actuators, the skid control ECU with
actuator inhibits the brake actuator control and inputs the mulfunction signal to the engine control module. According to the
mulfunction signal, the brake actuator turns off the solenoid and the engine control module rejects any electronically
controlled request from the VSC system. As a result, the vehicle functions without the ABS, BA, TRAC, and VSC systems.
A4, A5 ABS Speed Sensor Front LH, RH
1-2 : 1.4-1.8 kW (20°C, 68°F)
A24, A25 ABS Speed Sensor Rear LH, RH
1-2 : 0.9-1.3 kW (25°C, 77°F) (4WD)
1-2 : Max. 1.45 kW (25°C, 77°F) (2WD)
B4 Brake Warning SW
1-2 : Closed with the float down
S27 Skid Control ECU with Actuator
46-Ground : Approx. 12 volts with the ignition SW at ON position
27-Ground : Approx. 12 volts with the stop light SW on (Brake pedal depressed)
31-Ground : Always continuity
S15 Stop Light SW
2-1 : Closed with brake pedal depressed
System Outline
Service Hints

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)

Maintenance Log: SUVs and Trucks
6Required under the terms of the Emission Control Warranty.7 Inspect thickness measurement and disc runout.8 Applies to Land Cruiser, Sequoia, Tundra and 4Runner with 2UZFE. Required only for vehicles in California,
Massachusetts and New York.
9See page 37 for details.
120,000 Miles or 144 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 plugs (all models)6
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
__ Drive belts
__ Drive shaft boots3
__ Engine coolant9
__ E ngine valve clearance (except Tacoma
with 2TRFE)
__ Front differential oil (4WD models, Highlander, RAV4)
Additional Maintenance Items for Special Operating Conditions2
Driv ing in desert or on dirt roads:
qTi gh ten n uts and bolts on c hassis
Driving while towing:
qReplace automatic transmission fluid
qRepl ac e f ront differential oil (Highlander, RAV4 and all 4WD models)
qReplace manual transmission oil (RAV4, Tundra)
qR eplace rear differential oil, including limited slip (all models except 2WD
Hi gh land erand 2WD RAV4)
qReplace transfer case oil (4WD models)
qTighten nuts and bolts on chassis
Dealer Service Verification:
Dat e :
M ileage:
35
__ Exhaust pipes and mountings
__ Fuel lines and connections, fuel tank band
and fuel tank vapor vent system hoses
__ Fuel tank cap gasket
__ Manual transmission oil (RAV4, Tundra)
__ R adiat or core and condenser
__ Rear differential oil (all models except
2WD Highlander and 2WD RAV4)
__ St eerin g gear box
__ Steering linkage and boots
__ Transfer case oil (all 4WD models)

A93972
Disconnect
HookPin
Turn
A93973
Plunger
Push
Turn
Seal Packing
A53051
NutNutA61989
A
B A
A
A
A
AB 14-14
- ENGINE MECHANICALVALVE CLEARANCE (2AZ-FE)
2507 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(3) Turn the crankshaft counterclockwise, and discon-
nect the plunger knock pin from the hook.
(4) Turn the crankshaft clockwise, and check that the
slipper is pushed by the plunger.
13. INSTALL CYLINDER HEAD COVER SUB-ASSY
(a) Remove any old packing (FIPG) material.
(b) Apply seal packing to 2 locations as shown in the illustra-
tion.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the cylinder head cover within 5 minutes after
applying seal packing.

Do not start the engine for at least 2 hours after instal-
ling the cylinder head cover.
(c) Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque:
11 NVm (112 kgfVcm, 8 ftVlbf) for nut
11 NVm (112 kgfVcm, 8 ftVlbf) for bolt A
14 NVm (143 kgfVcm, 10 ftVlbf) for bolt B
14. INSTALL SPARK PLUG
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
15. INSTALL IGNITION COIL ASSY
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
16. INSTALL FRONT WHEEL RH
17. CHECK FOR ENGINE COOLANT LEAKS (See page 16-6)

W04200
Normal Signal Waveform
1 V / Division2 m/s / DivisionGND
BR3795OKNG Speed Sensor
8.0 NVm
(82 kgfVcm, 71 in.Vlbf)
No Clearance
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-793
983 Author
: Date
:
5 INSPECT SPEED SENSOR AND SENSOR ROTOR SERRATIONS
INSPECTION USING OSCILLOSCOPE
(a) Connect the oscilloscope to terminal FR+ - FR- or FL+
- FL- of the skid control ECU.
(b) Drive the vehicle at about 19 mph (30 km/h), and check
the signal waveform.
OK:
A waveform as shown in a figure should be output.
HINT:

As the vehicle speed (wheel revolution speed) increases,
a cycle of the waveform narrows and the fluctuation in the
output voltage becomes greater.

When noise is identified in the waveform on the oscillo-
scope, error signals are generated due to the speed sen-
sor rotor's scratches, looseness or foreign matter at-
tached to it.
NG Go to step 6
OK
REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37)
6 INSPECT FRONT SPEED SENSOR INSTALLATION
(a) Check the speed sensor installation.
OK:

The installation bolt is tightened properly.
Torque: 8.0 NVm (82 kgfVcm, 71 in.Vlbf)

There is no clearance between the sensor and the
front steering knuckle.
NOTICE:
Check the speed sensor signal after the replacement
(see page 05-765).
NG REPLACE FRONT SPEED SENSOR
(SEE PAGE 32-40)
OK