start TOYOTA HIGHLANDER HYBRID 2006 XU40 / 2.G Workshop Manual

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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.
Because of the added load of the trail-
er, your vehicle’s engine may overheat
on hot days (at temperatures over
30C [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 343 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 hybrid system. When restarting out after parking on a
slope:
1. With the transmission in the “P” posi- tion, start the hybrid system. 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.

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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
391 in Section 7 −2 for instructions.
Do not carry unnecessary weight in
your vehicle. Excess weight puts a
heavier load on the hybrid system,
causing greater fuel consumption.
Accelerate slowly and smoothly.
Avoid jackrabbit starts.
Avoid continuous changes of speed.
Stop −and− go driving wastes electric
power and 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.
When parking, be sure to put the
transmission into the “P” position. In
the “N” position, the gasoline engine
operates but electricity cannot be gen-
erated. The traction battery will be dis-
charged requiring unnecessary engine
power to recharge.
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 curbs and
slow down on rough roads. Improper
alignment not only causes faster tire
wear but also puts an extra load on
the hybrid system, 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.
How to save fuel and make
your vehicle last longer

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IN CASE OF AN EMERGENCY
In case of an emergency
If your vehicle will not start 340
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If your hybrid system stalls while driving 343
. . . . . . . . . . . . . . . . . . . . . . .
If your vehicle overheats 343
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
If you have a flat tire 344
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . . .
If your vehicle becomes stuck 354
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If your vehicle needs to be towed 354
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If you cannot shift transmission selector lever 359
. . . . . . . . . . . . . . . . . .
If you lose your keys 360
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . \
. . . .
If you lose your wireless remote control transmitter 360
. . . . . . . . . . . . .
SECTION 4

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Before making these checks, make sure
you have sufficient fuel and that you have
followed the correct starting procedure giv-
en in “How to start the hybrid system” on
page 326 in Section 3. If your vehicle is
equipped with the engine immobilizer sys-
tem, also check whether the other keys
will start the hybrid system. If they work,
your key may be broken. Have the key
checked at your Toyota dealer. If none of
your keys work, there may be a malfunc-
tion in the immobilizer system. Call your
Toyota dealer. (See “Keys (with engine
immobilizer system)” on page 22 in Sec-
tion 1−2.)
If the instrument cluster dims or the
instrument cluster display turns off
with the ignition on... 1. Check that the auxiliary battery termi- nals are tight and clean.
2. If the auxiliary battery terminals are O.K., the auxiliary battery is dis-
charged. You may try jump starting.
See “(b) Jump starting” on page 340
for further instructions.
NOTICE
Hybrid vehicles cannot be push
started.
If the instrument cluster displays with
normal brightness levels with the igni-
tion on...
The hybrid system may be faulty. Contact
your Toyota dealer. If the auxiliary battery is discharged,
the hybrid system can be started by
jump starting. Depending on the vehicle
condition, however, the hybrid system
may not start.
To avoid serious injury and damage to
your vehicle which might result from an
explosion of the battery, acid burns,
electrical burns, or damaged electronic
components, follow instructions careful-
ly.
If you are unsure about how to follow this
procedure, we strongly recommend that
you seek the help of a competent me-
chanic or towing service.
CAUTION
Batteries contain sulfuric acid
which is poisonous and corrosive.
Wear protective safety glasses when
jump starting, and avoid spilling
acid on your skin, clothing, or ve-
hicle.
If your vehicle will not start—
(a) Simple checks
(b) Jump starting

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If you should accidentally get acid
on yourself or in your eyes, remove
any contaminated clothing and flush
the affected area with water im-
mediately. Then get immediate medi-
cal attention. If possible, continue
to apply water with a sponge or
cloth while en route to the medical
office.
The gas normally produced by a
battery will explode if a flame or
spark is brought near. Use only
standardized jumper cables and do
not smoke or light a match while
jump starting.
NOTICE
The battery used for boosting must
be 12 V. Do not jump start unless you
are sure that the booster battery is
correct.
JUMP STARTING PROCEDURE
1. If the booster battery is installed in another vehicle, make sure the vehicles
are not touching. Turn off all unneces-
sary lights and accessories.
When boosting, use the battery of
matching or higher quality. Any other
battery may be difficult to jump start
with.
If jump starting is difficult, charge the
battery for several minutes.
2. If required, remove all the vent plugs from the booster and discharged batter-
ies. Lay a cloth over the open vents
on the batteries. (This helps reduce the
explosion hazard, personal injuries and
burns.)
3. If the engine in the vehicle with the booster battery is not running, start it
and let it run for a few minutes. During
jump starting, run the engine at about
2000 rpm with the accelerator pedal
lightly depressed.
Discharged
battery
Booster
battery
Positive
terminal
(“+” mark) Jumper cable Positive terminal
(“+”mark)
4. Make the cable connections in the or-
der a, b, c, d.
a. Connect the clamp of the positive
(red) jumper cable to the positive (+)
terminal of the discharged auxiliary bat-
tery.
b. Connect the clamp at the other end
of the positive (red) jumper cable to
the positive (+) terminal of the booster
battery.

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Jumper cable
Booster
battery
Discharged
battery
Negative terminal
(“− ”mark)
c. Connect the clamp of the negative
(black) jumper cable to the negative ( −)
terminal of the booster battery.
d. Connect the clamp at the other end
of the negative (black) cable to a solid,
stationary, unpainted metallic point
away from the auxiliary battery (such
as shown in the illustration). Do not
connect it to or near any part that may
move when the hybrid system is star-
ted.The recommended connecting points
are shown in the illustration.
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 the hybrid system. Make sure the “READY” light is on.
If the traction battery warning light
comes on in the meter cluster, the
traction battery is also discharged. In
this condition, the hybrid system will
not start. Contact your Toyota dealer.
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 the auxiliary battery dis-
charging is not apparent (for example,
lights left on), have the battery checked
by 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 the hybrid
system in the normal way.
If the another attempt is not successful,
the battery may be depleted. Have it ch-
ecked at your Toyota dealer.

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If your hybrid system stalls while driv-
ing...
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 hybrid
system again.
If the hybrid system will not start, see “If
your vehicle will not start”.
CAUTION
When the hybrid system is not oper-
ating, the power assist for the brakes
and steering will not work, so steer-
ing and braking will be much more
difficult than usual.
Any of the following may indicate that
the hybrid system has overheated:
The engine coolant temperature
gauge indicates overheating.
A “WATER TEMP” warning message
appears on the multiinformation
display.
A loss of power is experienced.
A loud knocking or pinging noise is
heard.
If the hybrid system overheats, follow
the procedures below: 1. Pull safely off the road, stop the ve- hicle and turn on your emergency
flashers. Put the hybrid 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 hybrid
system. Wait until the steam subsides
before opening the hood. If there is no
coolant boiling over or steam, leave the
ignition turned on 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 hybrid system is on, keep
hands and clothing away from the
moving fan.
4. If the coolant is leaking, stop the hy-
brid system 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 hy-
brid system is on. Fill it about half full.
For the coolant type, see “Coolant type
selection” on page 389 in Section 7 −2.
If your hybrid system stalls
while driving If your vehicle overheats

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CAUTION
Do not attempt to remove the radiator
cap when the hybrid system and ra-
diator are hot. Serious injury could
result from scalding hot fluid and
steam blown out under pressure.
6. After the coolant temperature has
cooled to normal, again check the cool-
ant level in the reservoir. If necessary,
bring it up to half full again. Serious
coolant loss indicates a leak in the
system. You s hould have it checked as
soon as possible at your Toyota dealer.
1. Reduce your speed gradually, keeping a straight line. Move cau-
tiously off the road to a safe place
well away from the traffic. Avoid
stopping on the center divider of
a highway. Park on a level spot
with firm ground.
2. Stop the hybrid system and turn on your emergency flashers.
3. Firmly set the parking brake and put the transmission in “P”.
4. Have everyone get out of the ve- hicle on the side away from traffic.
5. Read the following instructions thoroughly.CAUTION
When jacking, be sure to observe
the following to reduce the possi-
bility of personal injury:
Follow jacking instructions.
 Do not put any part of your
body under the vehicle sup-
ported by the jack. Otherwise,
personal injury may occur.
 Do not start the hybrid system
while your vehicle is supported
by the jack.
 Stop the vehicle on a level firm
ground, firmly set the parking
brake and put the transmission
in “P”. Block the wheel diago-
nally opposite to the one being
changed if necessary.
If you have a flat tire—

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CAUTION
Never get under the vehicle when
the vehicle is supported by the
jack alone.
6. Remove the wheel nuts and
change tires.
Lift the flat tire straight off and put it
aside.
Remove the wheel ornament from the
flat tire and replace it on the spare
wheel.
Roll the spare wheel into position and
align the holes in the wheel with the
bolts. Then lift up the wheel and get
at least the top bolt started through
its hole. Wiggle the tire and press it
back over the other bolts.Before putting on wheels, remove any
corrosion on the mounting surfaces
with a wire brush or such. Installation
of wheels without good metal− to−met-
al contact at the mounting surface can
cause wheel nuts to loosen and
eventually cause a wheel to come off
while driving.
—Changing wheels

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NOTICE
Only use specified towing eyelet;
otherwise your vehicle may be dam-
aged.
 Never tow a vehicle from the rear
with four wheels on the ground.
This may cause serious damage to
the transmission.
A driver must be in the vehicle to steer
it and operate the brakes.
Towing in this manner may be done only
on hard− surfaced roads for a short dis-
tance and at low speeds. Also, the
wheels, axles, drive train, steering and
brakes must all be in good condition.
CAUTION
Use extreme caution when towing ve-
hicles. Avoid sudden starts or erratic
driving maneuvers which would place
excessive stress on the emergency
towing eyelet and towing cable or
chain. The eyelet and towing cable or
chain may break and cause serious
injury or damage.
NOTICE
Use only a cable or chain specifically
intended for use in towing vehicles.
Securely fasten the cable or chain to
the towing eyelet provided.
Before towing, release the parking brake
and put the transmission in “N”. The key
must be in “ACC” (hybrid system off) or
“ON” (hybrid system on).
CAUTION
When the hybrid system is off, the
power assist for the brakes and steer-
ing will not work so steering and
braking will be much more difficult
than usual.1. Remove the front towing eyelet cover on the front bumper by pushing the
outside of the cover.
—Installing front towing eyelet