Repair Instruction: Precaution

1. HINTS ON OPERATIONS
   Fig 1: Precaution For - Basic Repair Hint

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. 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.
3. 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 any way, it must be recoated with the specified adhesive.
   3. When reusing a precoated part, clean off the old adhesive and dry the part with compressed air. Then apply new seal lock adhesive appropriately to that part.
   4. Some seal lock agents harden slowly. You may have to wait for the seal lock adhesive to harden.
   Fig 2: Identifying Seat Lock Adhesive

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. GASKETS
   1. When necessary, use a sealer on gaskets to prevent leaks.
5. BOLTS, NUTS AND SCREWS
   1. Carefully follow all the specifications for tightening torques. Always use a torque wrench.
6. FUSES
   1. When inspecting a fuse, check that the wire of the fuse is not broken.
   2. If the wire of a fuse is broken, confirm that there are no shorts in its circuit.
   3. 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.
   Fig 3: Identifying Fuses

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   FUSES SPECIFICATION
   
   

   Illustration	Symbol	Part Name	Abbreviation
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	FUSE	FUSE
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	MEDIUM CURRENT FUSE	M-FUSE
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	HIGH CURRENT FUSE	H-FUSE
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	FUSIBLE LINK	FL
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	CIRCUIT BREAKER	CB

7. clips
   1. The removal and installation methods of typical clips used for vehicle body parts are shown in the table below.

      HINT:

      If clips are damaged during a procedure, always replace the damaged clips with new ones.

   CLIPS REMOVAL/INSTALLATION CHART
   
   

   Shape (Example)	Removal/Installation
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

8. CLAWS
   1. The removal and installation methods of typical claws used for vehicle body parts are shown in the table below.

      HINT:

      If claws are damaged during a procedure, always replace the cap or cover that has damaged claws with a new one.

   CLAWS REMOVAL/INSTALLATION CHART
   
   

   Shape (Example)	Illustration	Procedures
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, disengage the claws and remove the cap or cover.
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, disengage the claws and remove the cap or cover.
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Using a screwdriver, detach the claws and remove the cap or cover.

9. HINGES, GUIDES, CLAMPS, PINS, AND ETC.
   1. The removal and installation methods of typical hinges, guides, clamps, and pins used for vehicle body parts are shown in the table below.

      HINT:

      If clamps are damaged during a procedure, always replace the cap or cover that has damaged clamps with a new one.

   HINGES, GUIDES, CLAMPS AND PINS REMOVAL/INSTALLATION CHART
   
   

   Shape (Example)	Removal/Installation
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002	Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

10. REMOVAL AND INSTALLATION OF VACUUM HOSES
    1. To disconnect a vacuum hose, pull and twist from the end of the hose. Do not pull from the middle of the hose as this may damage the hose.
       Fig 4: Precaution For - Vacuum Hoses

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
    3. After completing any hose related repairs, double check that the vacuum hoses are properly connected. The label under the hood shows the proper layout.
    4. When using a vacuum gauge, never force the hose onto a connector that is too large. If a hose has been stretched, air may leak. Use a step-down adapter if necessary.
    Fig 5: Identifying Vacuum Hoses With Tags

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. TORQUE WHEN USING TORQUE WRENCH WITH EXTENSION TOOL
    Fig 6: Identifying Torque Wrench With Extension Tool Length

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Use the formula below to calculate special torque values for situations where SST or an extension tool is combined with a torque wrench.

       Formula: T = (L2/(L1 + L2)) * T 

    TORQUE WRENCH FORMULA CHART
    
    

    T'	Reading of torque wrench {N*m (kgf*cm, ft.*lbf)}
    T	Torque {N*m (kgf*cm, ft.*lbf)}
    L1	Length of SST or extension tool {cm (in.)}
    L2	Length of torque wrench {cm (in.)}

    Fig 7: Identifying Torque Wrench With Extension Tool Length

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE: If an extension tool or SST is combined with a torque wrench and used to tighten to a torque specification in this service information, the actual torque will be excessive and parts will be damaged.

1. Technicians must undergo special training to be able to service and inspect the high-voltage system.
2. All high-voltage wire harnesses and connectors are colored orange. The HV battery and other high-voltage components have "High Voltage" caution labels. Do not carelessly touch these wires or components.
3. When there is a problem with the wire harness or connector of a high-voltage circuit, repairs to the harness or connector should not be attempted. Replace damaged or malfunctioning high voltage cables or connectors.
4. Before inspecting or servicing the high-voltage system, be sure to follow all safety measures, such as wearing insulated gloves and removing the service plug to prevent electrocution. Carry the removed service plug in your pocket to prevent other technicians from accidentally reconnecting it while you are servicing the vehicle.
   Fig 8: Identifying Rear Door Scuff Plate And Reclining Hinge Cover

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair information because this may cause a malfunction.
5. After removing the service plug, wait 5 minutes before touching any of the high-voltage connectors and terminals.

   HINT:

   Waiting for at least 5 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

6. Before wearing insulated gloves, make sure that they are not cracked, ruptured, torn, or damaged in any way. Do not wear wet insulated gloves.
7. When servicing the vehicle, do not carry metal objects like mechanical pencils or scales that can be dropped accidentally and cause a short circuit.
8. Before touching a bare high-voltage terminal, wear insulated gloves and use a tester to make sure that the terminal voltage is 0 V.
   Fig 9: Precaution For - Do Not Wear Gloves

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. After disconnecting or exposing a high-voltage connector or terminal, insulate it immediately using insulating tape.
10. Bolts and nuts high-voltage terminals should be tightened firmly to the specified torque. Both insufficient and excessive torque can cause failure.
    Fig 10: Insulating High-Voltage Connector Or Terminal

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. Use the "CAUTION: HIGH VOLTAGE. DO NOT TOUCH DURING OPERATION" sign to notify other technicians that the high-voltage system is being inspected and/or repaired.
    Fig 11: Caution: High Voltage. Do Not Touch During Operation

    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. After servicing the high-voltage system and before reinstalling the service plug, check again that you have hot left a part or tool inside, that the high-voltage terminals are firmly tightened, and that the connectors are correctly connected.
13. When installing hybrid system components such as the HV battery, make sure that the polarity of all connections is correct.

1. The HIGHLANDER HV automatically turns the engine on and off when the READY light on the instrument panel is illuminated. To avoid injury, make sure that both the indicator on the power switch and the READY light on the meter are off.

Fig 12: Identifying Multi-Information Display

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. If one of the warning lights (2) to (4) illuminates, connect Techstream to the DLC3 to check the DTCs (Diagnostic Trouble Codes). Then, refer to the applicable troubleshooting steps in this service information to inspect and repair the affected area. The foregoing actions are also required if the READY light does not illuminate when attempting to turn the power switch on (READY).
   INDICATOR LIGHT CHART
   
   

   Indicator Light	Vehicle Condition
   (1) READY (TO DRIVE)	Illuminates when the power switch is turned on (READY), indicating that the vehicle is ready to be driven.
   (2) Master Warning Light	The master warning light comes on or flashes along with a buzzer to indicate that a warning is currently being displayed on the multi-information display. Depending on the warning, the buzzer nay also sound. Example: Low engine oil pressure Hybrid system malfunction 4WD system malfunction Hybrid system overheat Tire pressure warning system malfunction VSC system malfunction EPS system malfunction Parking brake applied Shift lever in the P position Any door is opened while driving Moonroof is not fully closed Maintenance is required Low tire pressure
   (3) Check Engine Warning Light	Illuminates when there is a malfunction in the engine control system. (Illuminates when the power switch is on.)
   (4) Charge Warning Light	Illuminates when there is a malfunction in the charging system. (Be sure to check the DTC (Diagnostic Trouble Code) if this light illuminates together with the master warning light.)

HINT:

The HIGHLANDER HV uses a 12 V auxiliary and a 288 V hybrid vehicle battery. Therefore, there are two recharging methods when the batteries are depleted.

1. Perform this procedure when the auxiliary battery is fully depleted.

   HINT:

   The following problems indicate that the auxiliary battery is depleted:

   • No display appears on the instrument panel when the power switch is turned on (IG).
   • The hybrid system does not start.
   • The headlights are dim.
   • The sound from the horn is weak.
   NOTE: Never use a quick charger.
   1. Move the shift lever to the P position and engage the parking brake.
   2. Turn the power switch off and remove the key from the interior detection area.
   3. Using booster cables, connect the 12 V battery of the rescue vehicle and the auxiliary battery of the stalled vehicle, as shown in the illustration.
      BATTERY CONNECTING LOCATION CHART
      
      

      Connecting Sequence	Connecting Location
      1	Positive battery terminal of stalled vehicle
      2	Positive battery terminal of rescue vehicle
      3	Negative battery terminal of rescue vehicle
      4	Bracket on the cylinder head cover

   4. Start the engine of the rescue vehicle and run the engine at a speed slightly higher than usual.
   5. Turn the power switch on (READY).
   Fig 13: View Of Battery Of Rescue Vehicle And Auxiliary Battery Of Vehicle

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: Immediately disconnect the booster cables in the reverse order of connection after the hybrid system and the engine have started. Do not leave the booster cables connected because they are not designed for recharging purposes. If the hybrid system fails to start and the HV battery warning illuminates, the HV battery may be discharged.
   Fig 14: Identifying Multi-Information Display

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. When the hybrid vehicle battery is depleted:
   1. Replace the hybrid vehicle battery.

      HINT:

      When the hybrid vehicle battery is discharged or low, the Low Traction Battery is displayed, and DTC P3000-389 is stored in the hybrid vehicle control ECU.

1. Items to be prepared for the accident site
   • Protective clothing (insulated gloves, rubber gloves, goggles, and safety shoes)
   • Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a container, and dissolve it in water)
   • Red litmus paper
   • ABC fire extinguisher (effective against both oil flames and electrical flames)
   • A shop rag or piece of cloth (for wiping off the electrolyte)
   • Insulating tape (for insulating cable)
   • Electrical tester
2. Actions to be taken at the accident site
   CAUTION:

   • Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.
   • If the vehicle catches on fire, use an ABC fire extinguisher to extinguish the fire. Trying to extinguish a fire using only a small amount of water can be more dangerous than effective. Use a substantial amount of water or wait for firefighters.
   • Visually check the HV battery and the immediate area for any electrolyte leakage. Do not touch any leaked liquid because it could be highly alkaline electrolyte.
   • Work on the vehicle only after the vehicle has been pulled out of the water.
   1. Check the vicinity of the hybrid vehicle battery for any leakage of the electrolyte.
      CAUTION: Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.
   2. If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the following procedure.
      CAUTION: Be sure to wear insulated gloves, goggles, and safety shoes.
      Fig 15: Identifying Battery, Engine Room Relay Block And Inverter With Converter Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Turn the power switch off.

      HINT:

      If the power switch cannot be turned off, remove the IGCT fuse from the engine room relay block or disconnect the cable from the negative terminal of the auxiliary battery.

   4. Wear insulated gloves, and then remove the service plug.
      NOTE: After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair service information because this may cause a malfunction.
      Fig 16: Identifying IGCT Fuse

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Moving the damaged vehicle

   If any of the following conditions are met, tow the vehicle away using a tow truck.

   • One or more of the high-voltage components and cables are damaged.
   • Components related to driving, the transaxle, or the fuel system are damaged.
   • The master warning light is on.
   • The READY light does not come on when attempting to turn the power switch on (READY).
   CAUTION: Before towing the vehicle away using a tow truck, disconnect the cable from the negative (-) terminal of the auxiliary battery and remove the service plug.
   NOTE: Perform the procedure below if the READY light turns off, or there are abnormal noises, unusual smells, or strong vibrations while driving:
   1. Park the vehicle in a safe place.
   2. Shift the shift lever to the "P" position, and apply the parking brake.
   3. Turn the power switch off, and disconnect the power cable from the negative (-) terminal of the auxiliary battery.
   4. Remove the service plug while wearing insulated gloves.
4. Actions required after moving the damaged vehicle
   1. Procedure

      If you see any liquid on the road surface, it could be highly alkaline electrolyte leakage. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.

5. Items to be prepared (when repairing a damaged vehicle)
   • Protective clothing (Insulated gloves, rubber gloves, goggles, and safety shoes)
   • Saturated boric acid solution 20 L (obtain 800 g of boric acid powder, put it into a container, and dissolve it in water)
   • Red litmus paper
   • A shop rag or piece of cloth (for wiping off the electrolyte)
   • Insulating tape (for insulating cables)
   • Electrical tester
6. Precautions to be observed when servicing a damaged vehicle
   CAUTION: Always follow instructions to ensure safety.
   1. Wear insulated or rubber gloves, goggles, and safety shoes.
   2. Check the HV battery and immediate area for any electrolyte leakage.
      CAUTION:

      • Do not touch any leaked liquid because it could be highly alkaline electrolyte. Wear rubber gloves and goggles, neutralize the liquid with saturated boric acid solution, and then apply red litmus paper to the liquid. Check that the paper does not turn blue. Wipe the neutralized liquid with a shop rag or piece of cloth.
      • If the electrolyte comes in contact with your skin, use a saturated boric acid solution or a large amount of water to wash it off. If the electrolyte comes in contact with an article of clothing, take it off immediately.
      • If the electrolyte comes in contact with your eyes, call out loudly for help. Do not rub your eyes. Wash them immediately with a large amount of water and seek medical care.
   3. Do not touch any bare cables that could be high voltage cable. If a cable must be touched or if accidental contact is possible, follow the following instructions: 1) wear insulated gloves and goggles, 2) measure the voltage between the cable and body ground using an electrical tester, and 3) insulate the cable using insulating tape.
   4. If damage to any of the high-voltage components and cables is suspected, cut the high-voltage circuit using the procedure below.
      CAUTION: Do not touch any bare cables that may have high-voltage. If a cable must be touched or if accidental contact is possible, wear insulated gloves and insulate the cable using insulating tape.
   5. Turn the power switch off.

      HINT:

      If the power switch cannot be turned off, remove the IGCT fuse from the engine room relay block or disconnect the cable from the negative terminal of the auxiliary battery.

   6. Wear insulated gloves, and then remove the service plug.
      NOTE: After removing the service plug grip, do not turn the power switch on (READY), unless instructed by the repair service information because this may cause a malfunction.
      Fig 17: Identifying IGCT Fuse

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Precautions to be taken when disposing of the vehicle
   1. Disposing of HV battery

      When scrapping the vehicle, remove the HV battery from the vehicle and return it to the location specified by the manufacturer. Any damaged HV battery should also be returned to the specified location.

   CAUTION:

   • After removing the HV battery, keep it away from water. Water may heat the battery, resulting in a fire.
   • Accidents such as electric shocks could result if the vehicle and its HV battery are disposed of improperly or abandoned. Therefore, make sure to return any HV battery using the prescribed recovery route through a TOYOTA dealer.
8. Precautions to be observed when towing
   1. Tow the damaged vehicle with its front and rear wheels lifted off the ground.
   CAUTION: Towing the damaged vehicle with its wheels on the ground will cause the motor to generate electricity. This electricity could, depending on the nature of the damage, leak and cause a fire.
9. Towing with the 4 wheels on the ground
   CAUTION:

   • If the vehicle needs to be towed using a rope with all 4 wheels on the ground, do not exceed 30 km/h (19 mph) and tow only for a short distance and then have the vehicle towed by a truck.
   • Turn the power switch on (IG) and shift the shift lever to the N position.
   • If any abnormality is present in the damaged vehicle during towing, stop towing immediately.

This vehicle is equipped with a Supplemental Restraint System (SRS).

1. GENERAL NOTICE
   1. As malfunctions of the SRS are difficult to confirm, 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.
   2. Work must be started at least 90 seconds after the power switch is turned off and after the cable is disconnected from the negative (-) battery terminal.

      The SRS is equipped with a back-up power source. If work is started within 90 seconds after turning the power switch off and disconnecting the cable from the negative (-) battery terminal, the SRS may deploy. When the cable is disconnected from the negative (-) battery terminal, the clock and audio system memory is erased. Before starting work, make a note of the settings of each memory system. When work is finished, reset the clock and audio system as before.

      CAUTION: Never use a back-up power source (battery or other) to avoid erasing the system memory. The back-up power source may inadvertently power the SRS and cause it to deploy.
   3. In minor collisions where the SRS does not deploy, the steering pad, front passenger airbag assembly, driver side knee airbag assembly, front seat side airbag assembly, curtain shield airbag assembly and front seat outer belt assembly should be inspected before further use of the vehicle.
   4. Never use the SRS parts from another vehicle. When replacing parts, use new parts.
   5. Before repairs, remove the airbag sensor assemblies if impacts are likely to be applied to the sensor during repairs.
   6. Never disassemble and attempt to repair any airbag sensor assemblies or airbag assemblies.
      1. Steering pad
      2. Front passenger airbag assembly
      3. Driver side knee airbag assembly
      4. Front seat side airbag assembly
      5. Curtain shield airbag assembly
      6. Front seat outer belt assembly
   7. Replace the airbag sensor assemblies and the airbag assemblies if: 1) damage has occurred from being dropped, or 2) cracks, dents or other defects in the case, bracket or connector are present.
   8. Do not directly expose the airbag sensor assemblies or airbag assemblies to hot air or flames.
   9. Use a voltmeter/ohmmeter with high impedance (minimum = 10 kΩ) for troubleshooting electrical circuits.
   10. Information labels are attached to the SRS components. Follow the instructions on the labels.
   11. After work on the SRS is completed, check the SRS warning light.
2. SPIRAL CABLE
   1. The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, as otherwise cable disconnection and other problems may occur. Refer to the information about correct installation of the steering wheel (See INSTALLATION ).
   Fig 18: Locating Spiral Cable

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. STEERING PAD
   1. Always place a removed or new steering pad surface upward as shown in the illustration. Placing the steering pad of the pad surface facing down could cause a serious accident if the airbag deploys. Also, do not place anything on top of the steering pad.
      Fig 19: Identifying Correct And Incorrect Placing Steering Pad

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
      Fig 20: Precaution For - Never Measure Resistance Of Airbag Squib

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Grease or detergents of any kind should not be applied to the steering pad.
   4. Store the steering pad in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.
   5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of the vehicle or the steering pad by itself, the airbag should be deployed using SST before disposal (See DISPOSAL ). Deploy the airbag in a safe place away from electrical noise.
4. FRONT PASSENGER AIRBAG ASSEMBLY
   1. Always place a removed or new front passenger airbag assembly with the pad surface facing upward as shown in the illustration. Placing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag deploys.
      Fig 21: Identifying Correct And Incorrect Placing Front Passenger Airbag Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
      Fig 22: Precaution For - Never Measure Resistance Of Airbag Squib

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Grease or detergents of any kind should not be applied to the front passenger airbag assembly.
   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.
   5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of the vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See DISPOSAL ). Deploy the airbag in a safe place away from electrical noise.
5. DRIVER SIDE KNEE AIRBAG ASSEMBLY
   1. Always place a removed or new driver side knee airbag assembly with the airbag deployment direction facing upward. Placing the airbag assembly with the airbag deployment direction facing downward could cause a serious accident if the airbag deploys.
      Fig 23: Identifying Correct And Incorrect Placing Driver Side Knee Airbag Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
      Fig 24: Precaution For - Never Measure Resistance Of Airbag Squib

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Grease or detergents of any kind should not be applied to the driver side knee airbag assembly.
   4. Store the driver side knee airbag assembly where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.
   5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of a vehicle or driver side knee airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See DISPOSAL ). Deploy in a safe place, away from electrical noise.
6. FRONT SEAT SIDE AIRBAG ASSEMBLY
   1. Always place a removed or new front seat side airbag assembly with the airbag deployment direction facing up.
   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
      Fig 25: Precaution For - Never Measure Resistance Of Airbag Squib

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Grease or detergents of any kind should not be applied to the front seat side airbag assembly.
   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.
   5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See DISPOSAL ). Deploy the airbag in a safe place away from electrical noise.
7. CURTAIN SHIELD AIRBAG ASSEMBLY
   1. Always place a removed or new curtain shield airbag assembly in a clear plastic bag, and keep it in a safe place.
      Fig 26: Identifying Correct And Incorrect Placing Curtain Shield Airbag Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      CAUTION: The plastic bag should be disposed of after use.
      NOTE: Never disassemble the curtain shield airbag assembly.
   2. Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which could cause serious injury.
      Fig 27: Precaution For - Never Measure Resistance Of Airbag Squib

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Grease or detergents of any kind should not be applied to the curtain shield airbag assembly.
   4. Store the airbag assembly in an area where the ambient temperature is below 93°C (200°F), the humidity is not high and there is no electrical noise.
   5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed using SST before disposal (See DISPOSAL ). Deploy the airbag in a safe place away from electrical noise.
8. FRONT SEAT OUTER BELT ASSEMBLY (SEAT BELT PRETENSIONER)
   1. Never measure the resistance of the front seat outer belt assembly. This may cause the pretensioner of the front seat outer belt assembly to activate, which could cause serious injury.
      Fig 28: Precaution For - Never Measure Resistance Of Front Seat Outer Belt Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Never disassemble the front seat outer belt assembly.
   3. Never install the front seat outer belt assembly on another vehicle.
   4. Store the front seat outer belt assembly in an area where the ambient temperature is below 80°C (176°F), the humidity is not high and there is no electrical noise.
   5. Before using an electric welder anywhere on the vehicle, disconnect the center airbag sensor assembly connectors. These connectors contain shorting springs. This feature reduces the possibility of the airbag deploying due to current entering the squib wiring.
   6. When disposing of a vehicle or the front seat outer belt assembly unit by itself, the front seat outer belt assembly should be activated before disposal (See DISPOSAL ). Activate the front seat outer belt assembly in a safe place away from electrical noise.
   7. As the front seat outer belt assembly is hot after being activated, allow some time for it to cool down sufficiently before disposal. Never apply water to cool down the front seat outer belt assembly.
   8. Grease, detergents, oil or water should not be applied to the front seat outer belt assembly.
9. CENTER AIRBAG SENSOR ASSEMBLY
   1. Never reuse a center airbag sensor assembly that has been involved in a collision where the SRS has deployed.
   2. The connectors to the center airbag sensor assembly should be connected or disconnected with the sensor installed to the vehicle. If the connectors are connected or disconnected while the center airbag sensor assembly is not placed installed, the SRS may activate.
   3. Work must be started at least 90 seconds after the power switch is turned off and the cable is disconnected from the negative (-) battery terminal, even if only loosening the bolts of the center airbag sensor assembly.
10. WIRE HARNESS AND CONNECTOR
    1. All the connectors in the system are a standard yellow color. If the SRS wire harness has an open circuit or the connector becomes broken, replace it.

1. REMOVAL AND INSTALLATION OF BATTERY TERMINAL
   NOTE: Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.
   Fig 29: Identifying Cable From Negative (-) Battery Terminal

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   1. Before performing electrical work, disconnect the cable from the negative (-) battery terminal to prevent component and wire damage caused by accidental short circuits.
   2. When disconnecting the cable, turn the power switch and headlight switch off and loosen the cable nut completely. Perform these operations without twisting or prying the cable. Then disconnect the cable.
   3. Clock settings, radio settings, audio system memory, DTCs and other data are erased when the cable is disconnected from the negative (-) battery terminal. Write down any necessary data before disconnecting the cable.
2. HANDLING OF ELECTRONIC PARTS
   1. 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.
   2. Do not pull the wires when disconnecting electronic connectors. Pull the connector itself.
   3. Do not drop electronic components, such as sensors or relays. If they are dropped on a hard surface, they should be replaced.
      Fig 30: Precaution For - Handling Of Electronic Parts

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   4. When cleaning the engine with steam, protect the electronic components, air filter and emission-related components from water.
   5. Never use an impact wrench to remove or install temperature switches or temperature sensors.
   6. When measuring the resistance between terminals of a wire connector, insert the tester probe carefully to prevent terminals from bending.

1. PLACE FOR REMOVING AND INSTALLING FUEL SYSTEM PARTS
   1. Work in a location with good air ventilation that does not have welders, grinders, drills, electric motors, stoves, or any other ignition sources.
   2. Never work in a pit or near a pit as vaporized fuel will collect in those places.
2. REMOVING AND INSTALLING FUEL SYSTEM PARTS
   1. Prepare a fire extinguisher before starting the operation.
   2. To prevent static electricity, install a ground wire to the fuel changer, vehicle and fuel tank, and do not spray the surrounding area with water. Be careful when performing work in this area, as the work surface will become slippery. Do not clean up gasoline spills with water, as this may cause the gasoline to spread, and possibly create a fire hazard.
   3. Avoid using electric motors, working lights and other electric equipment that can cause sparks or high temperatures.
   4. Avoid using iron hammers as they may create sparks.
   5. Dispose of fuel-contaminated cloth separately using a fire resistant container.

1. If any metal particles enter intake system parts, this may damage the engine.
2. When removing and installing intake system parts, cover the openings of the removed parts and engine openings. Use adhesive tape or other suitable materials.
3. When installing intake system parts, check that no metal particles have entered the engine or installed parts.

Fig 31: Identifying Engine Intake Parts

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Before removing a hose, check the clamp position so that it can be reinstalled in the same position.
2. Replace any deformed or dented clamps with new ones.
3. When reusing a hose, attach the clamp on the clamp track portion of the hose.
4. For a spring type clamp, you may want to spread the tabs slightly after installation by pushing in the direction of the arrows as shown in the illustration.

Fig 32: Identifying Clamp Position

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the antenna far away from the ECU and sensors of the vehicle electronic systems as possible.
2. Install an antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle electronic systems. For details about ECU and sensor locations, refer to the information on the applicable components.
   Fig 33: Identifying Mobile Communication Systems

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Keep the antenna and feeder separate from other wirings as much as possible. This will prevent signals sent from the communication equipment from affecting vehicle equipment and vice-versa.
4. Check that the antenna and feeder are correctly adjusted.
5. Do not install a high-powered mobile communication system.

1. NOTICES FOR WHEN TESTING WITH 2WD CHASSIS DYNAMOMETER
   1. When testing with a 2WD chassis dynamometer such as a speedometer tester, a combination tester for the speedometer and brake, or a chassis dynamometer, enter 2WD inspection mode to turn TRAC and VSC operation off.
   NOTE:

   • If the vehicle is tested in normal mode on the chassis dynamometer, TRAC and VSC operation may cause the vehicle to jump out from the chassis dynamometer.
   • Check that "2WD Maintenance Mode" is displayed on the multi-information display.
   • Secure the vehicle with a lock chain for safety.

   HINT:

   Activating 2WD inspection mode (See INSPECTION MODE PROCEDURE )

2. NOTICES FOR VSC RELATED PROCEDURES
   1. For VSC related parts, adjustments are required after removal and installation. Therefore, perform removal and installation only when necessary.
   2. When performing VSC related procedures, be sure to strictly follow the preparation and completion procedures.
   3. When performing removal and installation or replacement of VSC related parts, first disconnect the cable from the negative (-) battery terminal.

1. Use one of the following methods to tow the vehicle.
2. Do not use any towing method other than those shown below.
   Fig 34: Towing Method Chart

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   NOTE: If the vehicle has trouble with the chassis or drivetrain, use method 1 (flat bed truck).
3. The following towing methods shown are dangerous and can damage the vehicle, so do not use them.

Fig 35: Precaution For - Vehicle Towing

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Use only unleaded gasoline.
2. Avoid idling the engine for more than 20 minutes.
3. Avoid performing unnecessary spark tests.
   1. Perform a spark test only when absolutely necessary. Perform this test as rapidly as possible.
   2. While testing, never race the engine unless instructed.
4. Avoid a prolonged engine compression measurement. Engine compression measurements must be performed as rapidly as possible.
5. 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.