engine TOYOTA HIGHLANDER 2007 XU40 / 2.G Repair Manual

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NOTICE
A large amount of unburned gases
flowing into the threeway catalytic
converter may cause it to overheat
and create a fire hazard. To prevent
this and other damage, observe the
following precautions:
Use only unleaded gasoline.
 Do not drive with an extremely low
fuel level; running out of fuel could
cause the engine to misfire, creat-
ing an excessive load on the three
way catalytic converter.
 Do not allow the engine to run at
idle speed for more than 20 min-
utes.
 Avoid racing the engine.
 Do not pushstart or pullstart your
vehicle.
 Do not turn off the ignition while
the vehicle is moving.
Keep your engine in good running
order. Malfunctions in the engine
electrical system, electronic ignition
system/distributor ignition system
or fuel systems could cause an ex-
tremely high threeway catalytic
converter temperature.
 If the engine becomes difficult to
start or stalls frequently, take your
vehicle in for a checkup as soon
as possible. Remember, your Toyota
dealer knows your vehicle and its
threeway catalytic converter sys-
tem best.
 To ensure that the threeway cata-
lytic converter and the entire emis-
sion control system operate proper-
ly, your vehicle must receive the
periodic inspections required by the
Toyota Maintenance Schedule. For
scheduled maintenance information,
refer to the “Scheduled Maintenance
Guide” or “Owner ’s Manual Supple-
ment”.CAUTION
Avoid inhaling the engine exhaust.
It contains carbon monoxide, which
is a colorless and odorless gas. It
can cause unconsciousness or even
death.
Make sure the exhaust system has
no holes or loose connections. The
system should be checked from
time to time. If you hit something,
or notice a change in the sound of
the exhaust, have the system
checked immediately.
Do not run the engine in a garage
or enclosed area except for the
time needed to drive the vehicle in
or out. The exhaust gases cannot
escape, making this a particularly
dangerous situation.
Do not remain for a long time in a
parked vehicle with the engine run-
ning. If it is unavoidable, however,
do so only in an unconfined area
and adjust the heating or cooling
system to force outside air into the
vehicle.
Engine exhaust cautions

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Keep the back door closed while
driving. An open or unsealed back
door may cause exhaust gases to
be drawn into the vehicle.
To allow proper operation of your
vehicle’s ventilation system, keep
the inlet grilles in front of the wind-
shield clear of snow, leaves, or oth-
er obstructions.
If you smell exhaust fumes in the
vehicle, open the windows and
close the back door to ensure
plenty of fresh air enters the ve-
hicle. If you can smell exhaust
fumes even though there are no
other vehicles in the surrounding
area, have your vehicle checked by
your Toyota dealer. Continued in-
halation of exhaust fumes can lead
to death by gas poisoning.
FUNCTIONS OF ENGINE OIL
Engine oil has the primary functions of
lubricating and cooling the inside of the
engine, and plays a major role in main-
taining the engine in proper working order.
ENGINE OIL CONSUMPTION
It is normal that an engine should con-
sume some engine oil during normal
engine operation. The causes of oil
consumption in a normal engine are as
follows.
Oil is used to lubricate pistons, piston
rings and cylinders. A thin film of oil
is left on the cylinder wall when a pis-
ton moves downwards in the cylinder.
High negative pressure generated when
the vehicle is decelerating sucks some
of this oil into the combustion chamber.
This oil as well as some part of the oil
film left on the cylinder wall is burned
by the high temperature combustion
gases during the combustion process.
Oil is also used to lubricate the stems
of the intake valves. Some of this oil
is sucked into the combustion chamber
together with the intake air and is
burned along with the fuel. High tem-
perature exhaust gases also burn the
oil used to lubricate the exhaust valve
stems. The amount of engine oil consumed de-
pends on the viscosity of the oil, the
quality of the oil and the conditions the
vehicle is driven under.
More oil is consumed by high
−speed driv-
ing and frequent acceleration and decel-
eration.
A new engine consumes more oil, since
its pistons, piston rings and cylinder walls
have not become conditioned.
Oil consumption: Max. 1.0 L per 1000
km (1.1 qt./600 miles, 0.9 Imp. qt./600
miles)
When judging the amount of oil con-
sumption, note that the oil may become
diluted and make it difficult to judge
the true level accurately.
As an example, if a vehicle is used for
repeated short trips, and consumes a nor-
mal amount of oil, the dipstick may not
show any drop in the oil level at all, even
after 1000 km (600 miles) or more. This
is because the oil is gradually becoming
diluted with fuel or moisture, making it
appear that the oil level has not changed.
The diluting ingredients evaporate out
when the vehicle is then driven at high
speeds, as on an expressway, making it
appear that oil is excessively consumed
after driving at high speeds.
Facts about engine oil
consumption

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IMPORTANCE OF ENGINE OIL LEVEL
CHECK
One of the most important points in prop-
er vehicle maintenance is to keep the en-
gine oil at the optimum level so that oil
function will not be impaired. Therefore, it
is essential that the oil level be checked
regularly. Toyota recommends that the oil
level be checked every time you refuel
the vehicle.
NOTICE
Failure to check the oil level regularly
could lead to serious engine trouble
due to insufficient oil.
For detailed information on oil level check,
see “Checking the engine oil level” on
page 378 in Section 7−2.
Your engine is fitted with iridiumtipped
spark plugs.
NOTICE
Use only iridiumtipped spark plugs.
Do not adjust gaps for engine perfor-
mance or smooth driveability.
The tandem master cylinder brake system
is a hydraulic system with two separate
sub −systems. If either sub −system s hould
fail, the other will still work. However, the
pedal will be harder to press, and your
stopping distance will increase. Also, the
brake system warning light may come on.
CAUTION
Do not drive your vehicle with only a
single brake system. Have your
brakes fixed immediately.
BRAKE BOOSTER
The brake booster uses engine vacuum to
power −assist the brakes. If the engine
should quit while you are driving, you can
bring the vehicle to a stop with normal
pedal pressure. There is enough reserved
vacuum for one or two stops—but no
more!
Iridiumtipped spark plugs Brake system

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CAUTION
Do not pump the brake pedal if the
engine stalls. Each push on the
pedal uses up your reserved vacu-
um.
Even if the power assist is com-
pletely lost, the brakes will still
work. But you will have to push the
pedal hard, much harder than nor-
mal. And your braking distance will
increase.
ANTILOCK BRAKE SYSTEM
(with “ABS” warning light)
The antilock brake system is designed
to help prevent lockup of the wheels
during a sudden braking or braking on
slippery road surfaces. This assists in
providing directional stability and steer-
ing performance of the vehicle under
these circumstances.
Effective way to press the ABS brake
pedal: When the anti −lock brake system
function is in action, you may feel the
brake pedal pulsating and hear a noise.
In this situation, to let the anti −lock
brake system work for you, just hold the
brake pedal down more firmly. Do not
pump the brake in a panic stop. This
will result in reduced braking performan-
ce.
The anti −lock brake system becomes op-
erative after the vehicle has accelerated
to a speed in excess of approximately 10
km/h (6 mph). It stops operating when the
vehicle decelerates to a speed below
approximately 5 km/h (3 mph).
Depressing the brake pedal on slippery
road surfaces such as on a manhole cov-
er, a steel plate at a construction site,
joints in a bridge, etc. on a rainy day
tends to activate the anti −lock brake sys-
tem.
You may hear a click or motor sound in
the engine compartment for a few seconds
when the engine is started or just after
the vehicle begins to move. This means
that the anti −lock brake system is in the
self −check mode, and does not indicate a
malfunction. When the antilock brake system is ac-
tivated, the following conditions may
occur. They do not indicate a malfunc-
tion of the system:
You may hear the anti
−lock brake sys-
tem operating and feel the brake pedal
pulsating and the vibrations of the ve-
hicle body and steering wheel. You
may also hear the motor sound in the
engine compartment even after the ve-
hicle is stopped.
At the end of the anti −lock brake sys-
tem activation, the brake pedal may
move a little forward.

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“ABS” warning light
The light comes on when the ignition key
is turned to the “ON” position. If the anti −
lock brake system and the brake assist
system work properly, the light turns off
after a few seconds. Thereafter, if the
system malfunctions, the light comes on
again.
When the “ABS” warning light is on (and
the brake system warning light is off), the
anti −lock brake system, the brake assist
system, the traction control system and
the vehicle stability control system do not
operate, but the brake system still oper-
ates conventionally.
When the “ABS” warning light is on (and
the brake system warning light is off), the
anti −lock brake system does not operate
so that the wheels could lock up during
a sudden braking or braking on slippery
road surfaces.
If either of the following conditions
occurs, this indicates a malfunction
somewhere in the components moni-
tored by the warning light system. Con-
tact your Toyota dealer as soon as
possible to service the vehicle.
The light does not come on when the
ignition key is turned to the “ON” posi-
tion, or remains on.
The light comes on while you are driv-
ing.
A warning light turning on briefly during
operation does not indicate a problem.
CAUTION
If the “ABS” warning light remains on
together with the brake system warn-
ing light, immediately stop your ve-
hicle at a safe place and contact your
Toyota dealer.
In this case, not only the antilock
brake system will fail but also the
vehicle will become extremely unsta-
ble during braking.
DRUMINDISC TYPE PARKING BRAKE
SYSTEM
Your vehicle has a drum −in −disc type
parking brake system. This type of brake
system n eeds bedding −down of the brake
shoes periodically or whenever the parking
brake shoes and/or drums are replaced.
Have your Toyota dealer perform the bed-
ding− down. BRAKE ASSIST SYSTEM
If you slam the brakes on such as in
an emergency or apply the brakes more
firmly than usual such as when de-
scending the hill with the designated
number of occupants in the vehicle, the
brake assist system provides more
powerful braking.
If you slam the brakes on or apply the
brakes more firmly, more powerful braking
will be applied. At this time, you may hear
a sound in the engine compartment and
feel the vibrations of the brake pedal. This
does not indicate a malfunction.
The brake assist system becomes opera-
tive after the vehicle has accelerated to
a speed in excess of approximately 10
km/h (6 mph). It stops operating when the
vehicle decelerates to a speed below
approximately 5 km/h (3 mph).
For an explanation of this system’s warn-
ing light, see “Service reminder indicators
and warning buzzers” on page 133 in Sec-
tion 1
−6.

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2.4 L 4cylinder (2AZFE) engine
3.3 L V6 (3MZFE) engine
The engine number is stamped on the
engine block as shown. Your new vehicle carries theft preven-
tion labels which are approximately 47
mm (1.85 in.) by 12 mm (0.47 in.).
The purpose of these labels is to reduce
the incidence of vehicle thefts by facilitat-
ing the tracing and recovery of parts from
stolen vehicles. The label is designed so
that once it is applied to a surface, any
attempt to remove it will result in destroy-
ing the integrity of the label. Transferring
these labels intact from one part to anoth-
er, will be impossible.
NOTICE
You should not attempt to remove the
theft prevention labels as it may vio-
late certain state or federal laws.
—Engine number
Theft prevention labels
(except for Canada)

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Ti r e relat ed ter mMeaning
Accessory weight
the combined weight (in excess of those standard items which may be
replaced) of automatic transmission, power steering, power brakes, power
windows, power seats, radio, and heater, to the extent that these items
are available as factory−installed equipment (whether installed or not)
Cold tire inflation pressure
tire inflation pressure when the vehicle has been parked for at least 3
hours or more, or it has not been driven more than 1.5 km or 1 mile
under that condition
Curb weight
the weight of a motor vehicle wi th standard equipment including the
maximum capacity of fuel, oil, and coolant, and, if so equipped, air
conditioning and additional weight optional engine
Intended outboard sidewall
(A) the sidewall that contains a whitewall, bears white lettering or bears manufacturer, brand, and/or model name molding that is higher or
deeper than the same molding on th e other sidewall of the tire, or
(B) the outward facing sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a vehicle
Maximum inflation pressurethe maximum cold inflation pressure to which a tire may be inflated and it
is shown on the sidewall of the tire
Maximum loaded vehicle weight
t he sum of —
(a) curb weight;
(b) accessory weight;
(c) vehicle capacity weight; and
(d) production options weight
—Glossary of tire terminology

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Vehicle load limits include total load
capacity, seating capacity, towing ca-
pacity and cargo capacity. Follow the
load limits shown below. Total load ca-
pacity and seating capacity are also
described on the tire and loading in-
formation label. For location of the tire
and loading information label, see
“Checking tire inflat ion pr es s ur e” on
page 383.
Total load capacity:
Without third seat390 kg (860 lb.)
With third seat 526 kg (1159 lb.)
Total load capacity means combined
weight of occupants, cargo and lug-
gage. Tongue load is included when
trailer towing.
Seating capacity:
Without third seatTotal 5 (Front 2, Rear 3)
With third seat
Total 7 (Front 2, Rear 5) Seating capacity means the maximum
number of occupants whose esti-
mated average weight is 68 kg (150
lb.) per person. Depending on the
weight of each person, the seating ca-
pacity given may exceed the total
load capacity.
NOTICE
Even if the number of occupants are
within the seating capacity, do not ex-
ceed the total load capacity.
Towing capacity:
2. 4 L 4 −cylinder (2AZ −FE) engine
Without towing package 680 kg (1500 lb.)
With towing package 1360 kg (3000 lb.)
3. 3 L V6 (3M Z −FE) engine
Without towing package
907 kg (2000 lb.)
With towing package 1585 kg (3500 lb.) Towing capacity means the maximum
gross trailer weight (trailer weight plus
its cargo weight) that your vehicle is
able to tow.
Cargo capacity
Cargo capacity may increase or de-
crease depending on the size (weight)
and the number of occupants. For de-
tails, see “—Capacity and distribu-
tion” on page 312.
CAUTION
Do not apply the load more than
each load limit. That may cause
not only damage to the tires, but
also deterioration to the steering
ability and braking ability, which
may cause an accident.
Veh icle lo ad limit s

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STARTING AND DRIVING
Starting and driving
Before starting the engine 316
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How to start the engine 316
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. .
Tips for driving in various conditions 317
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Off −road driving precautions 318
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Winter driving tips 319
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. . . . . .
Dinghy towing 320
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Trailer towing 321
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How to save fuel and make your vehicle last longer 326
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SECTION 3

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1. Check the area around the vehicle be-
fore entering it.
2. Adjust seat position, seatback angle, seat cushion angle, seat height, head
restraint height and steering wheel
angle.
3. Adjust the inside and outside rear view mirrors.
4. Lock all side doors and back door.
5. Fasten seat belts. 1. Apply the parking brake firmly.
2. Turn off unnecessary lights and acces-
sories.
3. Put the selector lever in “P”. If you need to restart the engine while the
vehicle is moving, put the selector le-
ver in “N”. A starter safety device will
prevent the starter from operating if the
selector lever is in any drive position.
4. Depress the brake pedal and hold it to the floor until driving off. Before starting the engine, be sure to fol-
low the instructions in “(a) Before crank-
ing”.
Normal starting procedure
The multiport fuel injection system/sequen-
tial multiport fuel injection system in your
engine automatically controls the proper
air
−fuel mixture for starting. You can start
a cold or hot engine as follows:
With your foot off the accelerator pedal,
crank the engine by turning the key to
“START”. Release it when the engine
starts.
Engine should be warmed up by driving,
not in idle. For warming up, drive with
smoothly turning engine until engine cool-
ant temperature is within normal range.
If the engine stalls...
Simply restart it, using the correct proce-
dure given in normal starting.
If the engine will not start...
See “If your vehicle will not start” on page
330 in Section 4.
Before starting the engine How to start the engine—
(a) Before cranking
(b) Starting the engine