engine TOYOTA HIGHLANDER HYBRID 2021 (in English) Repair Manual

4777-2. Steps to take in an emergency
7
When trouble arises
HIGHLANDER HV_U
The warning lights and warning buzzers operate as follows depend-
ing on the content of the message. If a message indicates the need
for inspection by a dealer, have the vehicle inspected by your To y o t a
dealer immediately.
*: A buzzer sounds the first time a message is shown on the multi-informa-
tion display.
■Warning messages
The warning messages explained
below may differ from the actual
messages according to operation
conditions and vehicle specifica-
tions.
■Warning buzzer
In some cases, the buzzer may not
be heard due to being in a noisy
location or audio sound.
■If “Engine Oil Level Low Add or
Replace” is displayed
The engine oil level is low. Check
the level of the engine oil, and add if
necessary.
This message may appear if the
vehicle is stopped on a slope. Move
the vehicle to a l evel surface and
check to see if the message disap-
pears.
Messages and warnings
Warning lightWarning
buzzer
*Warning
-Sounds
 Indicates an important situation, such as
when a system relate d to driving is mal-
functioning or that danger may result if
the correction procedure is not per-
formed
 Indicates a situation, such as when dam-
age to the vehicle or danger may result
Comes on or
flashesSounds
Indicates an importan t situation, such as
when the systems shown on the
multi-information display may be malfunc-
tioning
-Does not sound
 Indicates a condition, such as malfunc-
tion of electrical components, their condi-
tion, or indicates the need for
maintenance
 Indicates a situatio n, such as when an
operation has been performed incor-
rectly, or indicates how to perform an
operation correctly

4807-2. Steps to take in an emergency
HIGHLANDER HV_Uare shown on the multi-informa-
tion display, it may indicate a mal-
function. Immediat
ely stop the
vehicle and contact your Toyota
dealer.
• “Braking Power Low Stop in a
Safe Place See Owner's Manual”
• “Oil Pressure Low Stop in a Safe Place See Owner's Manual”
• “Charging System Malfunction Stop in a Safe Place See Owner's
Manual”
• “Stop in a Safe Place See Owner's Manual”
• “Shift to P See Owner's Manual”
●If any of the following messages
are shown on the multi-informa-
tion display, the vehicle may have
run out of fuel. Stop the vehicle in
a safe place and, if the fuel level is
low, refuel the vehicle.
• “Hybrid System Stopped”
• “Engine Stopped”
●If any of the following messages
are shown on the multi-informa-
tion display, it may indicate a mal-
function. Have the vehicle
inspected by you r Toyota dealer
immediately.
• “Hybrid System Malfunction”
• “Check Engine”
• “Hybrid Battery System Malfunc- tion”
• “Accelerator System Malfunction”
• “Smart Key System Malfunction
See Owner's Manual”
●If any of the following messages
are shown on the multi-informa-
tion display, follow the instruc-
tions.
• “Engine Coolant Temp High Stop in a Safe Place See Owner's Man-
ual” ( P.504)
• “Maintenance Required for Trac- tion Battery Cooling Parts See
Owner's Manual” ( P.441)
NOTICE
■If “High Power Consumption
Partial Limit on AC/Heater
Operation” is displayed fre-
quently
There is a possible malfunction
relating to the charging system or
the 12-volt battery may be deteri-
orating. Have the vehicle
inspected by you r Toyota dealer.

4917-2. Steps to take in an emergency
7
When trouble arises
HIGHLANDER HV_U
7Confirm it is not loose after
tightening:
1 Push and pull the tire
2 Try rotating
Visually check to ensure tire is not
hung on surrounding parts.
If looseness or misassembly exists,
repeat steps 2 to 7.
8 Repeat step 7, any time the
tire is lowered or disturbed.
9 Stow the jack and all tools.
■The compact spare tire
●The compact spare tire is identi-
fied by the label “TEMPORARY
USE ONLY” on the tire sidewall.
Use the compact spare tire tempo-
rarily, and only in an emergency.
●Make sure to check the tire infla-
tion pressure of the compact
spare tire. ( P.515)
■When using the compact spare
tire
As the compact sp are tire is not
equipped with a tire pressure warn-
ing valve and transmitter, low infla-
tion pressure of the spar e tire will
not be indicated by the tire pressure
warning system. Also, if you replace
the compact spare tire after the tire
pressure warning light comes on,
the light remains on.
■When the compact spare tire is
equipped
When driving with the compact spare tire installed, the vehicle
height will be diffe
rent than when
driving with standard tires.
■If you have a flat front tire on a
road covered with snow or ice
Install the compact spare tire on one
of the rear wheels of the vehicle.
Perform the following steps and fit
tire chains to the front tires:
1 Replace a rear tire with the com-
pact spare tire.
2 Replace the flat front tire with the
tire removed from the rear of the
vehicle.
3 Fit tire chains to the front tires.
WARNING
■When using the compact
spare tire
●Remember that the compact
spare tire provided is specifi-
cally designed for use with your
vehicle. Do not use your com-
pact spare tire on another vehi-
cle.
●Do not use more than one com-
pact spare tire simultaneously.
●Replace the comp act spare tire
with a standard tire as soon as
possible.
●Avoid sudden acceleration,
abrupt steering, sudden brak-
ing and shifting operations that
cause sudden engine braking.
■When the compact spare tire
is attached
The vehicle speed may not be
correctly detected, and the follow-
ing systems may not operate cor-
rectly:
• ABS & Brake assist
• VSC
• TRAC
• EPS

5007-2. Steps to take in an emergency
HIGHLANDER HV_U
on the second vehicle and connect the clamp at the other end of
the negative cable to .
Exclusive jump starting terminal (your vehicle)
Positive (+) battery terminal (second vehicle)
Negative (-) battery term inal (second vehicle)
Solid, stationary, unpainted metallic point away from the exclu sive
jump starting terminal and any m oving parts as shown in the illus-
tration
5 Start the engine of the sec-
ond vehicle. Increase the
engine speed slightly and
maintain at that level for
approximately 5 minutes to
recharge the 12-volt battery
of your vehicle.
6 Open and close any of the
doors of your vehicle with the
power switch OFF.
7 Maintain the engine speed of
the second vehicle and start
the hybrid system of your
vehicle by turning the power
switch to ON.
8 Make sure the “READY” indi-
cator comes on. If the indica- tor light does not come on,
contact your Toyota dealer.
9 Once the hybrid system has
started, remove the jumper
cables in the exact reverse
order from which they were
connected.
10Close the exclusive jump starting terminal cover, and
reinstall the fuse box cover to
its original position.
Once the hybrid system starts,
have the vehicle inspected at
your Toyota dealer as soon as
possible.

5047-2. Steps to take in an emergency
HIGHLANDER HV_U
If the engine coolant tempera-
ture gauge enters the red
zone or “Engine Coolant
Temp High Stop in a Safe
Place See Owner’s Manual”
is shown on the multi-informa-
tion display
1 Stop the vehicle in a safe
place and turn off the air con-
ditioning system, and then
stop the hybrid system.
2 If you see steam:
Carefully lift the hood after the steam subsides.
If you do not see steam:
Carefully lift the hood.
3 After the hybrid system has
cooled down sufficiently,
inspect the hoses and radia-
tor core (radiator) for any
leaks.
Radiator
Cooling fan
If a large amount of coolant leaks,
immediately contact your Toyota
dealer.
4The coolant level is satisfac-
tory if it is between the
“FULL” and “LOW” lines on
the reservoir.
Reservoir
“FULL” line
“LOW” line
If your vehicle over-
heats
The following may indicate
that your vehicle is over-
heating.
The needle of the engine
coolant temperature gauge
( P.89) enters the red zone
or a loss of hybrid system
power is experienced. (For
example, the vehicle speed
does not increase.)
 “Engine Coolant Temp High
Stop in a Safe Place See
Owner’s Manual” or “Hybrid
System Overheated Output
Power Reduced” is shown
on the multi-information dis-
play.
 Steam comes out from
under the hood.
Correction procedures

5057-2. Steps to take in an emergency
7
When trouble arises
HIGHLANDER HV_U
Radiator cap
5 Add coolant if necessary.
Water can be used in an emer-
gency if coolant is unavailable.
6Start the hybrid system and
turn the air conditioning sys-
tem on to check that the radi-
ator cooling fan operates and
to check for coolant leaks
from the radiator or hoses.
The fan operates when the air con-
ditioning system is turned on imme-
diately after a cold start. Confirm
that the fan is op erating by check-
ing the fan sound and air flow. If it is
difficult to check th ese, turn the air
conditioning system on and off
repeatedly. (The fan may not oper-
ate in freezing temperatures.)
7 If the fan is not operating:
Stop the hybrid system
immediately and contact your
Toyota dealer.
If the fan is operating:
Have the vehicle inspected at
the nearest Toyota dealer.
8 Check if “Engine Coolant
Temp High Stop in a Safe
Place See Owner's Manual”
is shown on the multi-infor-
mation display.
If the message does not disappear:
Stop the hybrid system and contact your Toyota dealer.
If the message is not displayed:
Have the vehicle inspected at the
nearest Toyota dealer.
If “Hybrid System Over-
heated Output Power
Reduced” is shown on the
multi-information display
1 Stop the vehicle in a safe
place.
2 Stop the hybrid system and
carefully lift the hood.
3 After the hybrid system has
cooled down, inspect the
hoses and radiator core (radi-
ator) for any leaks.
Radiator
Cooling fan
If a large amount of coolant leaks,
immediately contact your Toyota
dealer.
4The coolant level is satisfac-
tory if it is between the

5067-2. Steps to take in an emergency
HIGHLANDER HV_U
“FULL” and “LOW” lines on
the reservoir.
Reservoir
“FULL” line
“LOW” line
5 Add coolant if necessary.
Water can be used in an emer-
gency if coolant is unavailable.
6After stopping the hybrid sys-
tem and waiting for 5 minutes
or more, start the hybrid sys-
tem again and check if
“Hybrid System Overheated
Output Power Reduced” is
shown on the for the
multi-information display.
If the message does not disappear:
Stop the hybrid system and contact
your Toyota dealer.
If the message is not displayed:
The hybrid system temperature has
dropped and the vehicle may be
driven normally. However, if the m
essage appears
again frequently, contact your Toy-
ota dealer.
WARNING
■When inspecting under the
hood of your vehicle
Observe the following precau-
tions.
Failure to do so may result in seri-
ous injury such as burns.
●If steam is seen coming from
under the hood, do not open the
hood until the steam has sub-
sided. The engine compart-
ment may be very hot.
●After the hybrid system has
been turned off , check that the
“READY” indicator is off.
When the hybrid system is oper-
ating, the gasoline engine may
automatically start, or the cool-
ing fan may suddenly operate
even if the gasoline engine
stops. Do not touch or approach
rotating parts such as the fan,
which may lead to fingers or
clothing (especially a tie, a scarf
or a muffler) getting caught,
resulting in serious injury.
●Do not loosen the radiator cap
and the coolant reservoir caps
while the hybrid system and
radiator are hot.
High temperature steam or
coolant could spray out.
NOTICE
■When adding engine/power
control unit coolant
Add coolant slowly after the
hybrid system has cooled down
sufficiently. Adding cool coolant to
a hot hybrid system too quickly
can cause damage to the hybrid
system.

5118-1. Specifications
8
Vehicle specifications
HIGHLANDER HV_U
your Toyota. It is used in regis-
tering the ownership of your
vehicle.
Top left of the instrument
panel
The vehicle identification number is
stamped.
Left-hand side center pillar
This number is also on the Certifi-
cation Label.
■Engine number
The engine number is stamped
on the engine block as shown.
Engine
ModelA25A-FXS
Ty p e4-cylinder in line , 4-cycle, gasoline
Bore and stroke3.44  4.07 in. (87.5  103.48 mm)
Displacement151.8 cu. in. (2487 cm3)
Valve clearance (engine cold)Automatic adjustment
Fuel
Fuel typeUnleaded gasoline only
Octane Rating87 (Research Octane Number 91) or
higher
Fuel tank capacity
(Reference)17.1 gal. (65 L, 14.2 Imp. gal.)

5128-1. Specifications
HIGHLANDER HV_U
Front
Rear
■Oil capacity (Drain and
refillreference
*)
*: The engine oil capacity is a refer-
ence quantity to be used when
changing the engine oil. Warm up
the engine and turn off the hybrid
system, wait more than 5 min-
utes, and check the oil level on the dipstick.
■Engine oil selection
“Toyota Genuine Motor Oil” is
used in your Toyota vehicle. Use
Toyota approved “Toyota Genu-
ine Motor Oil” or equivalent to
satisfy the following grade and
viscosity.
Oil grade: API SN/RC multi-
grade engine oil
Recommended viscosity: SAE
0W-16
Electric motor (traction motor)
Ty p ePermanent magnet synchronous
motor
Maximum output134 kW
Maximum torque199 ft•lbf (270 N•m, 27.5 kgf•m)
Ty p ePermanent magnet synchronous
motor
Maximum output40 kW
Maximum torque89 ft•lbf (121 N•m, 12.3 kgf•m)
Hybrid battery (traction battery)
Ty p eNickel-Metal hydride battery
Vo l t a g e7.2 V/module
Capacity6.5 Ah (3HR)
Quantity40 modules
Nominal voltage288 V
Lubrication system
With filter4.8 qt. (4.5 L, 4.0 Imp.
qt.)
Without
filter4.4 qt. (4.2 L, 3.7 Imp.
qt.)

5138-1. Specifications
8
Vehicle specifications
HIGHLANDER HV_U
Outside temperature
SAE 0W-16 is the best choice
for good fuel economy and good
starting in cold weather.
If SAE 0W-16 is not available,
SAE 0W-20 oil may be used.
However, it must be replaced
with SAE 0W-16 at the next oil
change.
Oil viscosity (0W-16 is explained
here as an example):
• The 0W in 0W-16 indicates the characteristic of the oil
which allows cold startability.
Oils with a lower value before the W allow for easier starting
of the engine in cold weather.
• The 16 in 0W-16 indicates the viscosity characteristic of the
oil when the oil is at high tem-
perature. An oil with a higher
viscosity (one with a higher
value) may be better suited if
the vehicle is operated at high
speeds, or under extreme
load conditions.
How to read oil container label:
API registered mark is added to
some oil containers to help you
select the oil you should use.
Cooling system
Capacity
Gasoline
engine10.5 qt. (9.9 L , 8.7 Imp. qt.)
Power con-
trol unit2.0 qt. (1.9 L, 1.7 Imp. qt.)
Coolant type
Use either of the following:
 “Toyota Super Long Life Coolant”
 Similar high-quality et hylene glycol-based
non-silicate, non -amine, non-nitrite, and
non-borate coolant with long-life hybrid organic
acid technology
Do not use pla in water alone.