Toyota Highlander Service Manual: Precaution
(b) HINTS ON OPERATIONS
1 |
Looks |
- Always wear a clean uniform.
- Hat and safety shoes must be worn
|
2 |
Vehicle protection |
- Prepare a grille cover, fender cover, seat cover and floor mat
before starting the operation.
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3 |
Safe operation |
- When working with 2 or more persons, be sure to check safety for
one another.
- When working with the engine running, pay attention to providing
ventilation for exhaust fumes in the
workshop.
- If working on high temperature, high pressure, rotating, moving,
or vibrating parts, wear appropriate safety
equipment and take extra care not to injure yourself or others.
- When jacking up the vehicle, be sure to support the specified
location with a safety stand.
- When lifting up the vehicle, use appropriate safety equipment.
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4 |
Preparation of tools and
measuring gauge |
- Before starting operation, prepare a tool stand, SST, gauge,
oil, shop rag and parts for replacement.
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5 |
Removal and installation,
disassembly and assembly
operations |
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6 |
Removed parts |
- Place the removed parts in a separate box to avoid mixing them
up with the new parts or contaminating the
new parts.
- As for non-reusable parts such as a gasket, an O-ring, and a
self-locking nut, replace them with new ones
following the instructions in this manual.
- Retain the removed parts for customer inspection, if requested.
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(c) JACKING UP AND SUPPORTING VEHICLE
(1) Care must be taken when jacking up and supporting the vehicle. Be sure to
lift and support the
vehicle at the proper locations (see page 01-21 ).
d) PRECOATED PARTS
(1) Precoated parts are bolts and nuts, that are coated
with a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or
moved in anyway, it must be recoated with the specified
adhesive.
(3) When reusing precoated parts, clean off the old
adhesive and dry the part with compressed air.
Then apply new seal lock adhesive appropriate to
the bolts and nut.
NOTICE:
Perform the torque with the lower limit value of the torque
tolerance.
(4) Some seal lock agents harden slowly. You may
have to wait for the seal lock agent to harden.
(e) GASKETS
(1) When necessary, use a sealer on gaskets to prevent leaks.
(f) BOLTS, NUTS AND SCREWS
(1) Carefully follow all the specifications for tightening torques. Always
use a torque wrench.
(g) FUSES
(1) When replacing fuses, be sure that the new fuse
has the correct amperage rating. DO NOT exceed
the rating or use one with a lower rating.
Illustration |
Symbol |
Part Name |
Abbreviation |
|
|
FUSE |
FUSE |
|
|
MEDIUM CURRENT FUSE |
M-FUSE |
|
|
HIGH CURRENT FUSE |
H-FUSE |
(h) CLIPS
(1) The removal and installation methods of typical clips used in body parts
are shown in the table
below.
HINT:
If clips are damaged during a procedure, always replace the damaged clip with a
new clip.
Shape (Example) |
Removal/Installation |
|
Remove clips from front or rear using clip remover
or pliers. |
|
Remove fasteners with a clip remover or screwdriver. |
|
Remove clips with a wide scraper to prevent
panel damage. |
|
Remove rivet by pushing the center pin through and prying
out the rivet shell. |
|
Remove rivet by unscrewing the center pin and prying out
the rivet shell |
|
Remove rivet by prying out the pin and then prying out the
rivet shell |
(i) REMOVAL AND INSTALLATION OF VACUUM HOSES
(1) To disconnect vacuum hoses, pull and twist from
the end of the hose. Do not pull from the middle of
the hose as this may cause damage.
- When disconnecting vacuum hoses, use tags to
identify where they should be reconnected.
- After completing the job, double check that the vacuum
hoses are properly connected. The label under
the hood shows the proper layout.
- When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step-down
adapter for adjustment. Once the hose has been
stretched, it may leak air.
(j) TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL
- If SST or an extension tool is combined with the
torque wrench to extend its length, do not tighten
the torque wrench to the specified torque values in
this manual. The resulting torque will be excessive.
- Use the formula below to calculate special torque
values for situations where SST or an extension tool
is combined with the torque wrench.
- Formula: T' = T x L2/(L1 + L2)
T' |
Reading of torque wrench {NVm (kgfVcm, ftVlbf)} |
T |
Torque {NVm (kgfVcm, ftVlbf)} |
L1 |
Length of SST or extension tool (cm) |
L2 |
Length of torque wrench (cm) |
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
HINT:
The HIGHLANDER is equipped with a Supplemental Restraint System (SRS) and seat
belt pretensioner.
Failure to carry out the service operations in the correct sequence could cause
the SRS to unexpectedly
deploy during servicing and lead to serious injury.
Furthermore, if a mistake is made when servicing the SRS, it is possible that
the SRS may fail to operate
properly. Before servicing (including removal or installation of parts,
inspection or replacement), be sure to
read the following section carefully.
(a) GENERAL NOTICE
- Malfunction symptoms of the SRS are difficult to confirm so the
Diagnostic Trouble Codes (DTCs)
become the most important source of information when troubleshooting. When
troubleshooting
the SRS, always check the DTCs before disconnecting the battery (see page
05-1215 ).
- To avoid serious injury, servicing the SRS must be started at
least 90 seconds after:
- The ignition switch is turned to the LOCK position.
- The negative (-) terminal cable is disconnected from the battery.
(The SRS is equipped with a back-up power source. If work is started within
90 seconds of disconnecting
the negative (-) terminal cable from the battery, the SRS may deploy.)
Disconnecting the negative (-) terminal cable will erase the memory of all
vehicle systems. Initialize
the systems after disconnecting/reconnecting the cable.
CAUTION:
Never use a back-up power source (battery or other) in an attempt to avoid
erasing system memory.
The back-up power source inadvertently may inadvertently power the SRS and cause
it to deploy.
- In minor collisions where the SRS does not deploy, the horn button
assembly, instrument panel
passenger airbag assembly, front seat airbag assembly, curtain shield airbag
assembly and seat
belt pretensioner should be inspected before further use of the vehicle (see
pages 60-19 ,
60-31 , 60-40 , 60-46 , and 61-8 ).
- Never use SRS parts from another vehicle. When replacing parts, use new
parts.
- Before repairs, remove the airbag sensor if impacts are likely to be
applied to the sensor during
repairs
- Never disassemble and repair the airbag sensor assembly, horn button
assembly, instrument
panel passenger airbag assembly, front seat airbag assembly, curtain shield
airbag assembly
or seat belt pretensioner.
- Replace the center airbag sensor assembly, side airbag sensor
assembly, horn button assembly
or the instrument panel passenger airbag assembly, front seat airbag
assembly or curtain shield
airbag assembly if: 1) damage has occurred from being dropped, or 2) cracks,
dents or other
defects in the case, bracket or connector are present.
- Do not directly expose the airbag sensor assembly, the horn button
assembly, the instrument
panel passenger airbag assembly, front seat airbag assembly, the curtain
shield airbag assembly
or the seat belt pretensioner to hot air or flames.
- Use a voltmeter/ohmmeter with high impedance (10 kW/V minimum) for
troubleshooting electrical
circuits.
- Information labels are attached to the SRS components. Follow the
instructions on the labels.
- After work on the SRS is completed, check the SRS warning light (see
page 05-1207 ).
(b) SPIRAL CABLE (in Combination Switch)
- The steering wheel must be fitted correctly to the
steering column with the spiral cable at the neutral
position, otherwise cable disconnection and other
problems may occur. Refer to page 60-26 for information
about correct installation of the steering
wheel.
(c) HORN BUTTON ASSEMBLY (with Airbag)
- When removing the horn button assembly or handling a new horn button, it
should be placed with
the pad surface facing up. See illustration below.
Placing the horn button with the pad surface facing down may lead to a
serious accident if the
airbag accidently inflates. Also, do not place anything on top of the horn
button
- Never measure the resistance of the airbag squib. This may cause
the airbag to inflate, which
could cause serious injury.
- Grease or detergents of any kind should not be applied to the steering
wheel pad.
- Store the horn button assembly in an area where the ambient
temperature is below 93C
(200F), the humidity is not high and electrical noise is not nearby.
- When using electric welding anywhere on the vehicle, disconnect
the airbag ECU connectors
(4 pins). These connectors contain shorting springs. This feature reduces
the possibility of the
airbag or seat belt pretensioner deploying due to currents entering the
squib wiring.
- When disposing of the vehicle or the horn button assembly by
itself, the airbag should be inflated
using an SST before disposal (see page 60-19 ). Perform the operation in a
safe place away from
electrical noise.
(d) INSTRUMENT PANEL PASSENGER AIRBAG ASSY
- Always place a removed or new instrument panel passenger airbag
assembly with the airbag
inflation direction facing up.
Placing the airbag assembly with the airbag inflation direction facing down
could cause a serious
accident if the airbag inflates.
- Never measure the resistance of the airbag squib. This may cause the
airbag to inflate, which
could cause serious injury.
- Grease or detergents of any kinds should not be applied to the
instrument panel passenger airbag
assembly.
- Store the airbag assembly in an area where the ambient temperature is
below 93C (200F),
the humidity is not high and electrical noise is not nearby.
- When using electric welding anywhere on the vehicle, disconnect
the airbag ECU connectors
(4 pins). These connectors contain shorting springs. This feature reduces
the possibility of the
airbag deploying due to currents entering the squib wiring.
- When disposing of a vehicle or the airbag assembly unit by itself, the
airbag should be deployed
using SST before disposal (see page 60-31 ).
Activate in a safe place away from electrical noise.
(e) CURTAIN SHIELD AIRBAG ASSEMBLY
- Always place the removed or new curtain shield airbag assembly in
a clear plastic bag, and keep
it in a safe place.
NOTICE:
Plastic bag is not re-useable.
CAUTION:
Never disassemble the curtain shield airbag assembly.
- Never measure the resistance of the airbag squib. This may cause the
airbag to inflate, which
is very dangerous.
- Grease should not be attached to the curtain shield airbag
assembly, and the surface should not
be cleared with detergents of any kind.
Store the airbag assembly in an area where the ambient temperature is below
93C (200F),
the humidity is not high and electrical noise is not nearby.
- When using electric welding anywhere on the vehicle, disconnect
the airbag ECU connectors
(2 pins). These connectors contain shorting springs. This feature reduces
the possibility of the
airbag deploying due to currents entering the squib wiring.
- When disposing of a vehicle or the curtain shield airbag assembly unit,
the airbag should be
deployed using SST before disposal (see page 60-40 ).
Activate in a safe place away from electrical noise.
(f) FRONT SEAT AIRBAG ASSEMBLY
- Always place a removed or new front seat airbag assembly with the
airbag inflation direction facing
up. Placing the airbag assembly with the airbag inflation direction facing
downward could
cause a serious accident if the airbag deploys.
- Never measure the resistance of the airbag squib. This may cause
the airbag to inflate, which
is very dangerous.
- Grease should not be applied to the front seat airbag assembly,
and the airbag door should not
be cleaned with detergents of any kind.
- Store the airbag assembly in an area where the ambient temperature
is below 93C (200F),
the humidity is not high and electrical noise is not nearby.
- When using electric welding anywhere on the vehicle, disconnect
the airbag ECU connectors
(2 pins). These connectors contain shorting springs. This feature reduces
the possibility of the
airbag deploying due to currents entering the squib wiring.
- When disposing of a vehicle or the airbag assembly unit by itself,
the airbag should be deployed
using SST before disposal (see page 60-46 ).
Activate in a safe place away from electrical noise.
(g) SEAT BELT PRETENSIONER
- Never measure the resistance of the seat belt pretensioner. This
may cause the seat belt pretensioner
to activate, which is very dangerous.
- Never disassemble the seat belt pretensioner.
- Never install the seat belt pretensioner on another vehicle.
- Store the seat belt pretensioner in area where the ambient
temperature is below 80C (176F),
the humidity is not high and electrical noise is not nearby.
- When using electric welding anywhere on the vehicle, disconnect
the airbag ECU connectors
(2 pins). These connectors contain shorting springs. This feature reduces
the possibility of the
airbag deploying due to currents entering the squib wiring.
- When disposing of a vehicle or the seat belt pretensioner unit by
itself, the seat belt pretensioner
should be activated before disposal (see page 61-8 ). Activate in a safe
place away from electrical
noise.
- The seat belt pretensioner is hot after being activated, so allow
some time for it to cool down sufficiently
before disposal. Never apply water to cool down the seat belt pretensioner.
- Oil or water should not be put on the front seat outer belt, and
the front seat outer belt should
not be cleaned with detergents of any kind.
(h) AIRBAG SENSOR ASSEMBLY
- Never reuse an airbag sensor assembly that has been involved in a
collision where the SRS has
deployed.
- The connectors to the airbag sensor assembly should be connected
or disconnected with the
sensor mounted on the floor. If the connectors are connected or disconnected
while the airbag
sensor assembly is not mounted to the floor, it could cause accidental
deployment of the SRS.
- Work must be started at least 90 seconds after the ignition switch
is turned to the LOCK position
and the negative (-) terminal cable is disconnected from the battery, even
if only loosening the
set bolts of the airbag sensor assembly.
(i) WIRE HARNESS AND CONNECTOR
- The SRS wire harness is integrated with the instrument panel wire
harness assembly. All the connectors
in the system are a standard yellow color. If the SRS wire harness becomes
disconnected
or the connector becomes broken, repair or replace it.
2. ELECTRONIC CONTROL
(a) REMOVAL AND INSTALLATION OF BATTERY TERMINAL
- Before performing electronic work, disconnect the
battery negative (-) terminal cable beforehand to
prevent component and wire damage caused by
accidental short circuits.
- When disconnecting and installing the terminal
cable, turn the ignition switch and lighting switch
OFF and loosen the terminal nut completely. Perform
these operations without twisting or prying the
terminal. Remove the battery cable from battery
post.
- Clock settings, radio settings, DTCs and other data
are erased when the battery cable is removed. Before
removing the battery cable, record any necessary
data.
- When disconnecting the battery's negative (-) terminal
cable, re-initialize the following systems after
the completion of the operation.
(b) HANDLING OF ELECTRONIC PARTS
- Do not open the cover or case of the ECU unless
absolutely necessary. If the IC terminals are
touched, the IC may be rendered inoperative by
static electricity.
- To disconnect electronic connectors, pull the connector
itself, not the wires.
- Be careful not to drop electronic components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced.
- When cleaning the engine with steam, protect the
electronic components, air filter and emission-related
components from water.
- Never use an impact wrench to remove or install
temperature switches or temperature sensors.
- When checking the continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
3. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
- Work in a place with good air ventilation and without any ignition
sources, such as a welder, grinder,
drill, electric motor or stove.
- Never work in a place such as a pit or near a pit because
vaporized fuel will collect in those places.
(b) REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
- Prepare a fire extinguisher before starting operation.
- To prevent static electricity, install a ground on the fuel
changer, vehicle and fuel tank, and do
not spray the area with water. The work surface will become slippery. Do not
clean up spills with
water as this will spread and gasoline and create a fire hazard.
- Never use any electric equipment like an electric motor or a
working light, as they may create
sparks or high temperatures.
- Never use an iron hammer, as it may create sparks.
- Dispose of fuel-contaminated shop rags separately using a fire
resistant container.
4. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS
- If any metal particle enters the inlet pass, this may damage
the engine.
- When removing and installing the inlet system parts, cover
the openings of the removed parts and engine openings.
Use clean shop rags, gummed tape, or other suitable
materials.
- When installing the inlet system parts, check that no metal
particles have entered the engine or the installed part.
5. HANDLING OF HOSE CLAMPS
- Before removing the hose, check the clamp position so
that you can restore it in the same way.
- Replace deformed or dented clamps with new ones.
- When reusing a hose, attach the clamp on the clamp track
portion of the hose.
- For a spring type clamp, to spread the tabs slightly after
installation by pushing in the direction of the arrow marks
as shown in the illustration.
6. FOR VEHICLES EQUIPPED WITH MOBILE COMMUNICATION SYSTEMS
- Install the antenna as far away from the ECU and sensors
of the vehicle electronic systems as possible.
- Install an antenna feeder at least 20 cm (7.87 in.) away
from the ECU and sensors of the vehicle electronic systems.
For details of the ECU and sensors locations, refer
to the section on applicable components.
- Keep the antenna and feeder separate from other wirings
as much as possible. This will prevent signals from the
communication equipment from affecting vehicle equipment
and vice-versa.
- Check that the antenna and feeder are correctly adjusted.
- Do not install any high-powered mobile communication
system.
7. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRAC) SYSTEM
(a) When testing with a 2-wheel drum tester such as a speedometer tester, a
combination tester of the
speedometer and brake, a chassis dynamometer, or when jacking up the front
wheels and driving the
wheels, always turn the TRAC system OFF beforehand via the TRAC OFF switch
before testing.
NOTICE:
TRAC system OFF condition can be confirmed by the "TRAC OFF" warning indicator
light in the combination
meter.
8. FOR VEHICLES EQUIPPED WITH VEHICLE SKID CONTROL (VSC) SYSTEM
(a) NOTICES WHEN USING DRUM TESTER
- Before beginning testing, disable the Vehicle Skid
Control system (VSC). To disable the VSC, turn the
ignition switch OFF and connect SST to terminals
TS and CG of DLC3.
SST 09843-18040
NOTICE:
- Confirm that the VSC warning light blinks.
- VSC system will be reset when the engine is restarted.
- For safety, secure the vehicle with restraint chains
while using a wheel dynamometer.
(b) NOTICES OF RELATED OPERATIONS TO VSC
- Do not carry out unnecessary installation and removal
as it might affect the adjustment of VSC related
parts.
- Be sure to follow the instructions for work preparation
and final confirmation of proper operation of the
VSC system.
9. WHEN SERVICING FULL-TIME 4WD VEHICLES
(a) MEASURING POINTS FOR SPEEDOMETER TESTER
NOTICE:
- Tester with a function of load setting cannot be used.
- Inspection should be done in the front wheels.
- Do not start, accelerate nor decelerate the vehicle suddenly.
- Maximum vehicle speed must be below 60 km/h (when using free roller,
it must be below 50
km/h).
- Driving time should be within 1 minute.
- Place the front wheels onto the rollers.
- Set the rear wheels free by free rollers or rigid racks.
- Fasten the vehicle with the lock chain.
- Start the engine, and then measure the vehicle
speed by increasing the speed gradually in the D
range.
- After the measurement completion, decrease the
vehicle speed by brake gradually, and then stop the
vehicle.
(b) MEASURING POINTS FOR BRAKE TESTER
NOTICE:
- Tester with a function of load measurement cannot be used
- High-speed type brake cannot be used.
- Place the wheels to be measured (front or rear) onto the rollers.
- Shift the shift lever into neutral.
- Perform the measurement by driving the tester rollers.
HINT:
In case that the dragging force is over 10% of the load put on the axis,
inspection of the wheel's rotating
condition should be done with both of the left and right axes jacked up. If no
abnormality is found in the rotating
condition, adhesive torque of the viscous coupling causes the excessive dragging
fore and therefore it
means no problem exists in the vehicle.
(c) MEASURING POINTS FOR ON-VEHICLE BALANCER
- Jack up all 4 wheels with 2 post lifts.
- Fasten the vehicle by setting 2 pick-up stands in the
bottom of suspension arm's tip of the front wheels
or rear wheels to be measured.
- Support the vehicle with rigid racks so that vehicle
will not lean in the vehicle's front/rear direction.
- Release the parking brake.
- Check that no dragging force exists by turning each
wheel by hand.
- Set the wheel balancers.
- Measurement should be done by using both of engine
drive and wheel balancer roller drive.
NOTICE:
- Start the engine, and then increase the vehicle speed
gradually in the D range.
- Do not accelerate nor decelerate suddenly.
- Deceleration should be done by brake gradually.
- Take special care that the vehicle does not move.
- Measurement should be done quickly.
10. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER
CAUTION:
If a large amount of unburned gasoline or gasoline vapors flow into the
converter, it may cause oveheating
and create a fire hazard. To prevent this, observe the following precautions.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling..
Avoid idling the engine for more than 20 minutes..
(c) Avoid a spark jump test.
- Perform a spark jump test only when absolutely necessary. Perform
this test as rapidly as possible.
- While testing, never race the engine.
(d) Avoid a prolonged engine compression measurement..
Engine compression measurements must be performed as rapidly as possible..
(e) Do not run the engine when the fuel tank is nearly empty. This may cause the
engine to misfire and
create an extra load on the converter.
11. WHEN TOWING FULL-TIME 4WD VEHICLES
(a) Tow the vehicles with the 4 wheels touching the ground
or the 4 wheels held up. In case that an abnormality exists
in the chassis and drive train, tow the vehicle with the 4
wheels held up.
(b) Never tow the vehicle with either condition of the front
wheels only or the rear only held up.
NOTICE:
Towing with either condition of the front wheels only the
rear wheels only held up might cause the drive train
burned-out or the wheels flying off the dolly.
(c) Towing the vehicle should be done by one of the towing
methods as shown in the illustration.
(d) If the vehicle has a trouble in the chassis or drive train, use
the wheel lift type truck.
Towing Method |
Parking Brake |
Transaxle Shift
Lever Position |
Flat Bed Truck |
Applied |
Any Position |
Wheel Lift Type Truck |
Applied |
Any Position |
NOTICE:
Do not use any towing method other those shown above.
1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP THE VEHICLE
The vehicle must be unloaded before jacking up the vehicle. Never
jack up/lift up a heavily loaded vehicle.
When remo ...
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(a) Remove the video (video adapter) terminal together with
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