2006 TOYOTA HIGHLANDER HYBRID cooling

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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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2006 HIGHLANDER (Hybrid) from Mar. ’05 Prod. (OM48530U)
1. Windshield and rear window washer
fluid tank
2. Brake fluid reservoir
3. Engine oil level dipstick
4. Gasoline engine coolant reservoir
5. Engine oil filler cap
6. Inverter coolant reservoir
7. Fuse blocks
8. Gasoline engine coolant radiator
9. Condenser
10. Inverter coolant radiator
11. Electric cooling fans
12. Auxiliary battery
Engine compartment overview

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CAUTION
Never touch, remove or disassemble
high voltage parts and cables.
Touching, removing or disassem-
bling those parts and cables can
cause severe burns or electric
shock that may result in death or
serious injury. For the locations of
high voltage parts and cables, see
“—High voltage components” on
page 6 in Section 11.
When the hybrid system is on, keep
hands, clothing, and tools away
from the moving fan. (Removing
rings, watches, and ties is advis-
able.)
Right after driving, the engine
compartment—the engine, radiator,
exhaust manifold and spark plug
boots, etc.—will be hot. So be care-
ful not to touch them. Oil, fluids
and spark plugs may also be hot.
If the radiator is hot, do not remove
the radiator cap or loosen the drain
plugs to prevent burning yourself.
Do not leave anything that may
burn easily, such as paper or rags,
in the engine compartment.
Do not smoke, cause sparks or al-
low open flames around fuel or the
battery. Their fumes are flammable.
When the hybrid system is operat-
ing with the “READY” light on, the
engine may suddenly start in some
cases. When you inspect the engine
compartment, be sure to turn off
the hybrid system.
Do not get under your vehicle with
just the body jack supporting it. Al-
ways use automotive jack stands or
other solid supports.
Be sure that the ignition is off if
you work near the electric cooling
fans or radiator grille. With the
ignition on, the electric cooling fans
will automatically start to run if the
engine coolant temperature is high
and/or the air conditioning is on.
Use eye protection whenever you
work on or under your vehicle
where you may be exposed to flying
or falling material, fluid spray, etc.
Brake fluid can harm your hands or
eyes and damage painted surfaces.
If fluid gets on your hands or in
your eyes, flush the affected area
with clean water immediately. If you
still feel uncomfortable with your
hands or eyes, go to the doctor.
Used engine oil contains potentially
harmful contaminants which may
cause skin disorders such as in-
flammation or skin cancer, so care
should be taken to avoid prolonged
and repeated contact with it. To re-
move used engine oil from your
skin, wash thoroughly with soap
and water.
Do not leave used oil within the
reach of children.
Dispose of used oil and filter only
in a safe and acceptable manner.
Do not dispose of used oil and fil-
ter in household trash, in sewers or
onto the ground. Call your dealer or
a service station for information
concerning recycling or disposal.
Be extremely cautious when work-
ing on the auxiliary battery. It con-
tains poisonous and corrosive
sulfuric acid.

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Look at the seethrough coolant reser-
voir when the hybrid system is cold.
The coolant level is satisfactory if it is
between the “FULL” and “LOW” lines
on the reservoir. If the level is low, add
coolant. (For coolant types, see “Cool-
ant type selection” described below.)
The coolant level in the reservoir will vary
with hybrid system temperature. However,
if the level is on or below the “LOW” line,
add coolant. Bring the level up to the
“FULL” line.
If the coolant level drops within a short
time after replenishing, there may be a
leak in the system. Visually check the
radiator, hoses, radiator cap and drain
cock and water pump.
If you can find no leak, have your Toyota
dealer test the cap pressure and check
for leaks in the cooling system.
CAUTION
To prevent burning yourself, do not
remove the radiator cap when the
coolant may be hot.
Coolant type selection
Use of improper coolants may damage
your cooling system.
Only use “Toyota Super Long Life Coolant”
or similar high quality ethylene glycol
based non−silicate, non −amine, non −nitrite,
and non− borate coolant with long −life
hybrid organic acid technology. (Coolant
with long −life hybrid organic acid
technology is a combination of low
phosphates and organic acids.)
For the U.S.A.—“Toyota Super Long Life
Coolant” is a mixture of 50% coolant and
50% deionized water. This coolant pro-
vides protection down to about −35 C
( − 31 F).
For Canada—“Toyota Super Long Life
Coolant” is a mixture of 55% coolant and
45% deionized water. This coolant pro-
vides protection down to about −42 C
( − 44 F).
NOTICE
Do not use plain water alone.
Toyota recommends “Toyota Super Long
Life Coolant”, which has been tested to
ensure that it will not cause corrosion nor
result in malfunction of your coolant
system with pr oper usage. “Toyota Super
Long Life Coolant” is formulated with
long −life hybrid organic acid technology
and has been specifically designed to
avoid cooling system malfunction on
Toyota vehicles.
Please contact your Toyota dealer for
further details.

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NOTICE
If the wrong combination of tire and
chain is used, the chains could dam-
age the vehicle body.
CHAIN INSTALLATION
Install the chains on the front tires as
tightly as possible. Do not use tire
chains on the rear tires. Retighten
chains after driving 0.5—1.0 km
(1/4—1/2 mile).
When installing chains on your tires, care-
fully follow the instructions of the chain
manufacturer.
If wheel covers are used, they will be
scratched by the chain band, so remove
the covers before putting on the chains.
CAUTION
Do not exceed 50 km/h (30 mph) or
the chain manufacturer ’s recom-
mended speed limit, whichever is
lower.
Drive carefully avoiding bumps,
holes, and sharp turns, which may
cause the vehicle to bounce.
Avoid sharp turns or lockedwheel
braking, as use of chains may ad-
versely affect vehicle handling.
When driving with chains installed,
be sure to drive carefully. Slow
down before entering curves to
avoid losing control of the vehicle.
Otherwise an accident may occur.
WHEN TO REPLACE YOUR WHEELS
If you have wheel damage such as
bending, cracks or heavy corrosion, the
wheel should be replaced.
If you fail to replace a damaged wheel,
the tire may slip off the wheel or cause
loss of handling control.
WHEEL SELECTION
When replacing wheels, care should be
taken to ensure that the wheels are re-
placed by ones with the same load ca-
pacity, diameter, rim width, and offset.
Correct replacement wheels are available
at your Toyota dealer.
A wheel of a different size or type may
adversely affect handling, wheel and bear-
ing life, brake cooling, speedometer/odom-
eter calibration, stopping ability, headlight
aim, bumper height, vehicle ground clear-
ance, and tire or snow chain clearance to
the body and chassis.
Replacing wheels

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ENGINE
Valve clearance (engine cold), mm (in.):
Intake 0.15—0.25 (0.006—0.010)
Exhaust 0.25—0.35 (0.010—0.014)
Spark plug type: DENSO SK20R11
NGK IFR6A11
Spark plug gap, mm(in.): 1.1 (0.043)
ENGINE LUBRICATION
Oil capacity (drain and ref ill), L (qt., Imp.
qt.): With filter 4.7 (5.0, 4.1)
Without filter 4.5 (4.8, 4.0)
“Toyota Genuine Motor Oil” is used in
your Toyota vehicle. Use Toyota approved
“Toyota Genuine Motor Oil” or equivalent
to satisfy the following grade and
viscosity.
Oil grade: API grade SL “Energy −Conserving” or
ILSAC multigrade engine oil Recommended oil viscosity:
SAE 5W −30
Outside temperature
Please contact your Toyota dealer for fur-
ther details. COOLING SYSTEM
Total capacity, L (qt., Imp. qt.):
Gasoline engine coolantWith rear heater 11.6 (12.3, 10.2)
Without rear heater
10.3 (10.9, 9.0)
Inverter coolant 3.4 (3.6, 3.0)
Coolant type: “Toyota Super Long Life Coolant” is
used in your Toyota vehicle at factory
fill. In order to avoid technical problems,
only use “Toyota Super Long Life
Coolant” or similar high quality ethylene
glycol based non −silicate, non −amine,
non− nitrite, and non− borate coolant with
long− life hybrid organic acid technology.
(Coolant with long −life hybrid organic
acid technology is a combination of low
phosphates and organic acids.)
Do not use plain water alone.
Please contact your Toyota dealer for
further details.
Service specifications

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Engine compartment
Fuses (type A)
1. ETCS 10 A: Hybrid system
2. DC/DCS 10 A: Hybrid system
3. ABS NO.2 10 A: Electronically con-
trolled brake system
4. ABS NO.1 10 A: Electronically con-
trolled brake system
5. BATT FAN 15 A: Hybrid system
6. ABS NO.3 15 A: Electronically con-
trolled brake system
7. OIL PUMP 10 A: Transmission fluid
cooling system
8. ST 7.5 A: Hybrid system
Engine compartment
9. RR HTR 15 A: Rear heater system
10. DRL 7.5 A: Daytime running light sys-
tem
11. HLP L LWR 15 A: Left−hand head-
light (low beam)
12. HLP L UPR 15 A: Left−hand headlight
(high beam)
13. HLP R UPR 15 A: Right−hand head-
light (high beam)
14. PWR OUTLET NO.2 20 A: Power out-
let (115 VAC)
15. TOWING 20 A: Trailer lights
Instrument panel
16. HAZ 15 A: Turn signal lights, emergen-
cy flashers
17. SECURITY 15 A: Theft deterrent sys-
tem
18. AM2 NO.1 30 A: “IGN”, “IG2” and “ST”
fuses
19. MPXB1 7.5 A: Electric power steering
system
20. HORN 10 A: Horns
21. RADIO NO.1 25 A: Audio system

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56. TAIL 10 A: Parking lights, tail lights,
side marker lights, license plate lights,
front fog lights
57. PANEL 7.5 A: Instrument panel lights
Fuses (type B)
58. ABS MTR2 30 A: Electronically con-
trolled brake system
59. ABS MTR1 30 A: Electronically con-
trolled brake system
60. HEATER 50 A: Air conditioning system,
“WATER PUMP” fuse
61. RR HTR 30 A: Rear heater system
62. RR DEF 30 A: Rear window defogger
63. RDI FAN NO.1 40 A: Electric cooling
fan
64. RDI FAN NO.2 40 A: Electric cooling
fan
65. MAIN 40 A: “H−LP L LWR”, “H −LP L
UPR”, “H− LP R LWR”, “H −LP R UPR”
and “DRL” fuses
66. IGCT NO.1 50 A: “INV W/P”, “IGCT
NO.2”, “IGCT NO.3”, “IGCT NO.4” and
“IGCT NO.5” fuses
67. AM1 40 A: “ECU−IG”, “WASHER”,
“IG1”, “WIPER”, “RR WIP”, “HEATER
(10 A)”, “RAD NO.2” and “CIG” fuses
68. POWER 30 A: Power seat Fuses (type C)
69. DC/DC 120 A: Hybrid system