brake TOYOTA HIGHLANDER 2005 XU20 / 1.G Service Manual

’05 HIGHLANDER_U (L/O 0409)
319
2005 HIGHLANDER from Nov. ’04 Prod. (OM48570U)
NOTICE
Do not crank for more than 30 se-
conds at a time. This may overheat
the starter and wiring systems.
 Do not race a cold engine.
 If the engine becomes difficult to
start or stalls frequently, have the
engine checked immediately.
Always slow down in gusty crosswinds.
This will allow you much better control.
Drive slowly onto curbs and, if pos-
sible, at a right angle. Avoid driving
onto high, sharp −edged objects and
other road hazards. Failure to do so
can lead to severe tire damage such
as a tire burst.
Drive slowly when passing over bumps
or travelling on a bumpy road. Other-
wise, the impact could cause severe
damage to the tires and/or wheels.
When parking on a hill, turn the front
wheels until they touch the curb so
that the vehicle will not roll. Apply the
parking brake, and place the transmis-
sion in “P”. If necessary, block the
wheels.
Washing your vehicle or driving through
deep water may get the brakes wet. To
see whether they are wet, check that
there is no traffic near you, and then
press the pedal lightly. If you do not
feel a normal braking force, the brakes
are probably wet. To dry them, drive
the vehicle cautiously while lightly
pressing the brake pedal with the park-
ing brake applied. If they still do not
work safely, pull to the side of the road
and call a Toyota dealer for assistance.
CAUTION
Before driving off, make sure that
the parking brake is fully released
and the parking brake reminder
light is off.
Do not leave your vehicle unat-
tended while the engine is running.
Do not rest your foot on the brake
pedal while driving. It can cause
dangerous overheating, needless
wear, and poor fuel economy.
To drive down a long or steep hill,
reduce your speed and downshift.
Remember, if you ride the brakes
excessively, they may overheat and
not work properly.
Be careful when accelerating, up-
shifting, downshifting or braking on
a slippery surface. Sudden accelera-
tion or engine braking, could cause
the vehicle to skid or spin.
Tips for driving in various
conditions

’05 HIGHLANDER_U (L/O 0409)
320
2005 HIGHLANDER from Nov. ’04 Prod. (OM48570U)
Do not drive in excess of the speed
limit. Even if the legal speed limit
permits it, do not drive over 140
km/h (85 mph) unless your vehicle
has highspeed capability tires.
Driving over 140 km/h (85 mph) may
result in tire failure, loss of control
and possible injury. Be sure to con-
sult a tire dealer to determine
whether the tires on your vehicle
are highspeed capability tires or
not before driving at such speeds.
Do not continue normal driving
when the brakes are wet. If they are
wet, your vehicle will require a
longer stopping distance, and it
may pull to one side when the
brakes are applied. Also, the park-
ing brake will not hold the vehicle
securely.
When driving your vehicle off −road, please
observe the following precautions to en-
sure your driving enjoyment and to help
prevent the closure of areas to off −road
vehicles.
a. Drive your vehicle only in areas where off−road vehicles are permitted to trav-
el.
b. Respect private property. Get owner ’s permission before entering private prop-
erty.
c. Do not enter areas that are closed. Honor gates, barriers and signs that re-
strict travel.
d. Stay on established roads. When condi- tions are wet, driving techniques should
be changed or travel delayed to pre-
vent damage to roads.
For owners in U.S. mainland, Hawaii and
Puerto Rico:
To obtain additional information pertaining
to driving your vehicle off −road, consult
the following organizations.
State and Local Parks and Recreation
Departments
State Motor Vehicle Bureau
Recreational Vehicle Clubs
U.S. Forest Service and Bureau of
Land Management
CAUTION
Always observe the following precau-
tions to minimize the risk of serious
personal injury or damage to your ve-
hicle:
Drive carefully when off the road.
Do not take unnecessary risks by
driving in dangerous places.
Do not grip the steering wheel
spokes when driving offroad. A
bad bump could jerk the wheel and
injure your hands. Keep both hands
and especially your thumbs on the
outside of the rim.
Always check your brakes for effec-
tiveness immediately after driving in
sand, mud, water or snow.
After driving through tall grass,
mud, rock, sand, rivers, etc., check
that there is no grass, bush, paper,
rags, stone, sand, etc. adhering or
trapped on the underbody. Clear off
any such matter from the under-
body. If the vehicle is used with
these materials trapped or adhering
to the underbody, a breakdown or
fire could occur.
Offroad driving precautions

’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 offroad 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 offroad
driving that has taken you through
rough terrain, sand, mud, or water.
For scheduled maintenance informa-
tion, refer to the “Scheduled Main-
tenance Guide” or “Owner’s Manual
Supplement”.Make sure your coolant is properly pro-
tected against freezing.
Only use “Toyota Super Long Life Coolant”
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 level”
on page 383 in Section 7 −2 for details of
coolant type selection.
For the U.S.A.—“Toyota Super Long Life
Coolant” is a mixture of 50% coolant and
50% deionized water. This coolant pro-
vides protection down to about −35 C
( − 31 F).
For Canada—“Toyota Super Long Life
Coolant” is a mixture of 55% coolant and
45% deionized water. This coolant pro-
vides protection down to about −42 C
( − 44 F).
NOTICE
Do not use plain water alone.
Winter driving tips

’05 HIGHLANDER_U (L/O 0409)
322
2005 HIGHLANDER from Nov. ’04 Prod. (OM48570U)
Check the condition of the battery and
cables.
Cold temperatures reduce the capacity of
any battery, so it must be in top shape
to provide enough power for winter start-
ing. Section 7−3 tells you how to visually
inspect the battery. Your Toyota dealer
and most service stations will be pleased
to check the level of charge.
Make sure the engine oil viscosity is
suitable for the cold weather.
See page 380 in Section 7 −2 for recom-
mended viscosity. Leaving a heavy sum-
mer oil in your vehicle during winter
months may cause harder starting. If you
are not sure about which oil to use, call
your Toyota dealer—they will be pleased
to help.
Keep the door locks from freezing.
Squirt lock de −icer or glycerine into the
locks to keep them from freezing.
Use a washer fluid containing an anti-
freeze solution.
This product is available at your Toyota
dealer and most auto parts stores. Follow
the manufacturer ’s directions for how
much to mix with water.NOTICE
Do not use engine antifreeze or any
other substitute because it may dam-
age your vehicle’s paint.
Do not use your parking brake when
there is a possibility it could freeze.
When parking, put the transmission into
“P” and block the rear wheels. Do not use
the parking brake, or snow or water accu-
mulated in and around the parking brake
mechanism may freeze, making it hard to
release.
Keep ice and snow from accumulating
under the fenders.
Ice and snow built up under your fenders
can make steering difficult. During bad
winter driving, stop and check under the
fenders occasionally.
Depending on where you are driving,
we recommend you carry some emer-
gency equipment.
Some of the things you might put in the
vehicle are tire chains, window scraper,
bag of sand or salt, flares, small shovel,
jumper cables, etc.
Your vehicle is not designed to be
dinghy towed (with four wheels on the
ground) behind a motorhome.
NOTICE
Do not tow your vehicle with four
wheels on the ground. This may
cause serious damage to your vehicle.
Dinghy towing

’05 HIGHLANDER_U (L/O 0409)
325
2005 HIGHLANDER from Nov. ’04 Prod. (OM48570U)
Never load the trailer with more
weight in the back than in the
front. About 60% of the trailer load
should be in the front half of the
trailer and the remaining 40% in the
rear.
HITCHES
If you wish to install a trailer hitch, you
should consult with your Toyota dealer.
Use only a hitch recommended by the
hitch manufacturer and the one which
conforms to the total trailer weight
requirement.
The hitch must be bolted securely to
the vehicle frame and installed accord-
ing to the hitch manufacturer ’s instruc-
tions.
The hitch ball and king pin should have
a light coat of grease.
Toyota recommends removing the trail-
er hitch whenever you are not towing
a trailer to reduce the possibility of
additional damage caused by the hitch
if your vehicle is struck from behind.
After removing the hitch, seal any
mounting holes in the vehicle body to
prevent entry of pollutants such as ex-
haust fumes, dirt, water, etc.
NOTICE
Do not use axlemounted hitches as
they can cause damage to the axle
housing, wheel bearings, wheels or
tires.
BRAKES AND SAFETY CHAINS
Toyota recommends trailers with
brakes that conform to any applica-
ble federal and state/provincial regu-
lations.
A safety chain must always be used
between the towing vehicle and the
trailer. Leave sufficient slack in the
chain for turns. The chain should
cross under the trailer tongue to
prevent the tongue from dropping to
the ground in case it becomes dam-
aged or separated. For correct safety
chain procedures, follow the hitch or
trailer manufacturer ’s recommenda-
tions.
CAUTION
If the total trailer weight exceeds
453 kg (1000 lb.), trailer brakes are
required.
Never tap into your vehicle’s hy-
draulic system as it would lower its
braking effectiveness.
Never tow a trailer without using a
safety chain securely attached to
both the trailer and the vehicle. If
damage occurs to the coupling unit
or hitch ball, there is danger of the
trailer wandering over into another
lane.
TIRES
Ensure that your vehicle’s tires are
properly inflated. See page 385 in Sec-
tion 7−2 and page 410 in Section 8 for
instructions.
The trailer tires should be inflated to
the pressure recommended by the trail-
er manufacturer in respect to the total
trailer weight.

’05 HIGHLANDER_U (L/O 0409)
327
2005 HIGHLANDER from Nov. ’04 Prod. (OM48570U)
Backing with a trailer is difficult and
requires practice. Grip the bottom of
the steering wheel and move your hand
to the left to move the trailer to the
left. Move your hand to the right to
move the trailer to the right. (This pro-
cedure is generally opposite to that
when backing without a trailer.) Also,
just turn the steering wheel a little at
a time, avoiding sharp or prolonged
turning. Have someone guide you when
backing to reduce the risk of an acci-
dent.
Because stopping distance may be in-
creased, vehicle−to −vehicle distance
should be increased when towing a
trailer. For each 16 km/h (10 mph) of
speed, allow at least one vehicle and
trailer length between you and the ve-
hicle ahead. Avoid sudden braking as
you may skid, resulting in jackknifing
and loss of control. This is especially
true on wet or slippery surfaces.
Avoid jerky starts or sudden accelera-
tion.
Avoid jerky steering and sharp turns.
The trailer could hit your vehicle in a
tight turn. Slow down before making a
turn to avoid the necessity of sudden
braking.
Remember that when making a turn,
the trailer wheels will be closer than
the vehicle wheels to the inside of the
turn. Therefore, compensate for this by
making a larger than normal turning
radius with your vehicle.
Crosswinds and rough roads will ad-
versely affect handling of your vehicle
and trailer, causing sway. Pay attention
to the rear from time to time to pre-
pare yourself for being passed by large
trucks or buses, which may cause your
vehicle and trailer to sway. If swaying
happens, firmly grip the steering wheel
and reduce speed immediately but
gradually. Never increase speed. Steer
straight ahead. If you make no extreme
correction with the steering or brakes,
the vehicle and trailer will stabilize.
Be careful when passing other ve-
hicles. Passing requires considerable
distance. After passing a vehicle, do
not forget the length of your trailer and
be sure you have plenty of room be-
fore changing lanes.
In order to maintain engine braking effi-
ciency, do not use overdrive.
Because of the added load of the trail-
er, your vehicle’s engine may overheat
on hot days (at temperatures over
30 C [85 F]) when going up a long or
steep grade with a trailer. If the engine
coolant temperature gauge indicates
overheating, immediately turn off the air
conditioning (if in use), pull off the road
and stop in a safe spot. Refer to “If
your vehicle overheats” on page 336 in
Section 4.
Always place wheel blocks under both
the vehicle and trailer wheels when
parking. Apply the parking brake firmly.
Put the transmission in “P”. Avoid park-
ing on a slope with a trailer, but if it
cannot be avoided, do so only after
performing the following:
1. Apply the brakes and hold.
2. Have someone place wheel blocks un- der both the vehicle and trailer wheels.
3. When the wheel blocks are in place, release your brakes slowly until the
blocks absorb the load.
4. Apply the parking brake firmly.
5. Shift into “P” and turn off the engine.

’05 HIGHLANDER_U (L/O 0409)
328
2005 HIGHLANDER from Nov. ’04 Prod. (OM48570U)
When restarting out after parking on a
slope:
1. With the transmission in “P” position, start the engine. Be sure to keep the
brake pedal depressed.
2. Shift into gear.
3. Release the parking brake and brake pedal and slowly pull or back away
from the wheel blo cks. Stop and apply
your brakes.
4. Have someone retrieve the blo cks.CAUTION
Do not exceed 72 km/h (45 mph) or
the posted towing speed limit,
whichever is lower. Because insta-
bility (swaying) of a towing vehicle
trailer combination usually in-
creases as the speed increases, ex-
ceeding 72 km/h (45 mph) may
cause loss of control.
Slow down and downshift before
descending steep or long downhill
grades. Do not make sudden down-
shifts.
Avoid holding the brake pedal down
too long or too frequently. This
could cause the brakes to overheat
and result in reduced braking effi-
ciency.
Improving fuel economy is easy—just take
it easy. It will help make your vehicle last
longer, too. Here are some specific tips
on how to save money on both fuel and
repairs:
Keep your tires inflated at the cor-
rect pressure. Underinflation causes
tire wear and wastes fuel. See page
385 in Section 7 −2 for instructions.
Do not carry unneeded weight in
your vehicle. Excess weight puts a
heavier load on the engine, causing
greater fuel consumption.
Avoid lengthy warmup idling. Once
the engine is running smoothly, begin
driving—but gently. Remember, howev-
er, that on cold winter days this may
take a little longer.
Keep the automatic transmission
overdrive turned on when engine
braking is not required. Driving with
the overdrive off will reduce the fuel
economy. (For details, see “Automatic
transmission” on page 147 in Section
1 −7.)
Accelerate slowly and smoothly.
Avoid jackrabbit starts. Get into high
gear as quickly as possible.
How to save fuel and make
your vehicle last longer

’05 HIGHLANDER_U (L/O 0409)
329
2005 HIGHLANDER from Nov. ’04 Prod. (OM48570U)
Avoid long engine idling. If you have
a long wait and you are not in traffic,
it is better to turn off the engine and
start again later.
Avoid engine lugging or overrev-
ving. Use a gear position suitable for
the road on which you are travelling.
Avoid continuous speeding up and
slowing down. Stop−and− go driving
wastes fuel.
Avoid unnecessary stopping and
braking. Maintain a steady pace. Try
to time the traffic signals so you only
need to stop as little as possible or
take advantage of through streets to
avoid traffic lights. Keep a proper dis-
tance from other vehicles to avoid sud-
den braking. This will also reduce wear
on your brakes.
Avoid heavy traffic or traffic jams
whenever possible.
Do not rest your foot on the brake
pedal. This causes premature wear,
overheating and poor fuel economy.
Maintain a moderate speed on high-
ways. The faster you drive, the greater
the fuel consumption. By reducing your
speed, you will cut down on fuel con-
sumption.
Keep the front wheels in proper
alignment. Avoid hitting the curb and
slow down on rough roads. Improper
alignment not only causes faster tire
wear but also puts an extra load on
the engine, which, in turn, wastes fuel.
Keep the bottom of your vehicle free
from mud, etc. This not only lessens
weight but also helps prevent corro-
sion.
Keep your vehicle tunedup and in
top shape. A dirty air cleaner, improp-
er valve clearance, dirty plugs, dirty oil
and grease,brakes not adjusted, etc. all
lower engine performance and contrib-
ute to poor fuel economy. For longer
life of all parts and lower operating
costs, keep all maintenance work on
schedule, and if you often drive under
severe conditions, see that your vehicle
receives more frequent maintenance.
(For scheduled maintenance informa-
tion, please refer to the “Scheduled
Maintenance Guide” or “Owner ’s Manu-
al Supplement”.)
CAUTION
Never turn off the engine to coast
down hills. Your power steering and
brake booster will not function with-
out the engine running. Also, the
emission control system operates
properly only when the engine is run-
ning.

’05 HIGHLANDER_U (L/O 0409)
335
2005 HIGHLANDER from Nov. ’04 Prod. (OM48570U)
Do not connect it to or near any part
that moves when the engine is
cranked.
CAUTION
When making the connections, to
avoid serious injury, do not lean over
the battery or accidentally let the
jumper cables or clamps touch any-
thing except the correct battery termi-
nals or the ground.
5. Start your engine in the normal way.
After starting, run it at about 2000 rpm
for several minutes with the accelerator
pedal lightly depressed.
6. Carefully disconnect the cables in the exact reverse order: the negative cable
and then the positive cable.
7. Carefully dispose of the battery cover cloths—they may now contain sulfuric
acid.
8. If removed, replace all the battery vent plugs.
If the cause of your battery discharging is
not apparent (for example, lights left on),
you should have it checked at your Toyota
dealer. If the first start attempt is not success-
ful...
Check that the clamp on the jumper
cables are tight. Recharge the discharged
battery with the jumper cables connected
for several minutes and restart your en-
gine in the normal way.
If the another attempt is not successful,
the battery may be depleted. Have it ch-
ecked at your Toyota dealer.
If your engine stalls while driving...
1. Reduce your speed gradually, keeping a straight line. Move cautiously off the
road to a safe place.
2. Turn on your emergency flashers.
3. Turn the ignition key to “ACC” or “LOCK”, and try starting the engine
again.
If the engine will not start, see “If your
vehicle will not start” on page 332 in this
Section.CAUTION
If the engine is not running, the pow-
er assist for the brakes and steering
will not work so steering and braking
will be much harder than usual.
If your engine stalls while
driving

’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 “ACC” or
“LOCK” 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 “P”
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 theradiator, 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
selection” 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 incr ease engine
speed If your vehicle overheats