Toyota Highlander Hybrid 6 2005-06

Sunroof

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Power Sunroof



Initialization Procedure
Highlander Hybrid

NOTE
When disconnecting the cable from negative (-) battery terminal, initialize the following system(s) after the terminal is reconnected:



SFI (fuel injection) system
 
Power window control system
 
Sunroof system
 

  1. PERFORM INITIALIZATION
    1. Apply the parking brake and chock the vehicle.
    2.  
    3. Connect the intelligent tester to the DLC3.

      Click image to see an enlarged view

      Fig. Connect the intelligent tester to the DLC3

    4.  
    5. Put the engine in the inspection mode.
    6.  
    7. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATA LIST / PRIMARY / COOLANT TEMP.
    8.  
    9. Warm up the engine with the A/C switch off until the coolant temperature is 83°C or more.
    10.  
    11. Select the following menu items: DIAGNOSIS /HV CONTROL ECU / DATALIST / SOC.
    12.  
    13. Move the shift lever to the N position, set the A/C switch to MAX cool or turn on the front defroster, and leave the vehicle until the SOC value is below 40%.
      NOTE
      If the SOC is substantially below 40%, the auxiliary battery may go dead. Therefore, do not allow the SOC to reach substantially below 40%.

    14.  
    15. Move the shift lever to the P position and turn the ignition switch OFF .
    16.  
    17. Disconnect the negative terminal from the auxiliary battery and leave it for 1 minute or more.
    18.  
    19. Reconnect the negative terminal to the auxiliary battery and turn the ignition switch ON .
    20.  
    21. Select the following menu items: DIAGNOSIS / ENHANCED OBD II / DATALIST / PRIMARY / COOLANT TEMP.
    22.  
    23. Check that the engine coolant temperature is 83°C or more.
      NOTE
      If the engine coolant temperature is below 83°C, start the engine by depressing the accelerator pedal with the shift lever in the P position to increase the coolant temperature.

    24.  
    25. Select the following menu items: DIAGNOSIS / ENHANCED OBDII / DATA LIST / CALCLOAD.
    26.  
    27. Move the shift lever to the D position while depressing the brake pedal with the left foot.
    28.  
    29. Depress the accelerator pedal with the right foot while firmly depressing the brake pedal with the left foot, and maintain an engine load value of 45% or more (60 to 70% of full acceleration) for approximately 30 seconds.
      WARNING
      Do not perform this step for 40 seconds or more.

    30.  
    31. Shift the shift lever to the P position. Turn the ignition switch off and then wait for 5 seconds before putting the vehicle into the READY-on state again.
    32.  
    33. Select the following menu items: DIAGNOSIS / ENHANCED OBDII / DATA LIST / ISC LEARNING.
    34.  
    35. Check that the air conditioner is off. Lightly depress the accelerator pedal and release it when the engine starts.
    36.  
    37. Check that "COMPLETE" is displayed on the intelligent tester screen.
      NOTE
      If "ISC LEARNING" is not completed within 1 minute, repeat steps (o) through (r). The engine will usually stop when "ISC LEARNING" is completed. However, the engine will not stop even when "ISC LEARNING" is completed in such cases when the charge level of the auxiliary battery is decreased.

    38.  

  2.  
  3. RESET (INITIALIZE) POWER WINDOW REGULATOR MOTOR
    NOTE
    Resetting the power window motor (initializing the pulse sensor) is necessary when the battery terminal is disconnected; when the power window regulator master switch, power window regulator switch, wire harness, power window regulator and power window motor are replaced or removed/ installed; or when the P FR DOOR fuse, ECU-B fuse and IG1 fuse are replaced. AUTO operation function, jam protection function and remote operation function via the power window regulator master switch do not operate without resetting.


    NOTE
    Be sure to reset the power window regulator motors using the power window switch on each door because the motors cannot be reset by remote operation using the power window master switch.


    WARNING
    In order to prevent a large amount of current from flowing in the wires, do not simultaneously reset 2 or more power window regulator motors.


    NOTE
    If the power window switch has been continuously operated for a long time, the power window regulator motor will stop so that no additional load will be applied to the motor. Continuing to operate the switch even after the motor has stopped will cause the switch to blink while restricting the AUTO UP/DOWN function and the remote UP/DOWN function. If this happens, reset the motor again after several minutes have passed.


    NOTE
    Whenever disconnecting the battery terminal, reset all the other systems besides the power window control system.

    1. Turn the ignition switch ON .
    2.  
    3. Halfway open the power window by pressing the power window switch.
    4.  
    5. Fully pull up the switch until the power window is fully closed and continue to hold the switch for approx. 1 second after the power window is fully closed.
    6.  
    7. Check that the AUTO UP/DOWN function operates normally. If the AUTO UP/DOWN function operates normally, reset operations have been completed at this time. If not normal, proceed with the steps.
    8.  
    9. Disconnect the negative battery terminal for 10 seconds.
    10.  
    11. Connect the battery terminal.
    12.  
    13. Turn the ignition switch ON .
    14.  
    15. Halfway open the power window by pressing the power window switch.
    16.  
    17. If the AUTO UP/DOWN function operates normally, reset operations have been completed at this time. If not normal, follow steps below.
    18.  
    19. Turn the ignition switch ON .
    20.  
    21. Halfway open the power window by pressing the power window switch.
    22.  
    23. Fully pull up the switch until the power window is fully closed and continue to hold the switch for approx. 12 seconds after the power window is fully closed.
    24.  
    25. Check that the AUTO UP/DOWN function operates normally.
    26.  

  4.  
  5. RESET SLIDING ROOF DRIVE GEAR SUBASSEMBLY
    NOTE
    When disconnecting the cable from the negative (-) battery terminal, or disconnecting the sliding roof drive gear or connector, sliding roof drive gear requires initialization of the pulse sensor. If a reset is not executed, the following functions do not operate: auto operation, jam protection function, key off operation, key-linked open and close, transmitter-linked open and close.

    1. Turn the ignition switch ON .
    2.  
    3. If the sliding roof is opened, close it fully.
    4.  
    5. Push the open switch of the slide switch or the up switch of the tilt switch on the personal light, making the sliding roof operation as follows: Tilt up - Approximately 1 second - tilt down - slide open - slide close
    6.  
    7. Sliding roof stops at the fully closed position.
    8.  
    9. Finish the initialization.
    10.  
    11. Check that the operation works normally with AUTO operation.
      NOTE
      If the following conditions occur while operating, initialization will fail.


      NOTE
      If the sliding roof cannot fully close or its position has become misaligned, perform the initialization again. If the sliding roof TILT UP switch or SLIDE CLOSE switch is pressed and held until the roof glass has either stopped moving or started moving in the opposite direction, and then the switch is held for another 10 seconds or more, perform the initialization again. If the AUTO operation function and jam protection function do not operate after the drive gear has been reset, replace the sliding roof drive gear (sliding roof ECU).



      Ignition switch is turned off.
       
      Pushed switch is released while sliding roof is operating.
       
      Vehicle speed is 5 km/h (3 mph) or higher.
       
      Battery of sliding roof ECU is 1 V or higher.
       
      Communication is cut off.
       

    12.  

  6.  

Removal & Installation
Motor

NOTE
This procedure requires removing the headlining assembly, which may require the help of an assistant.

  1. Remove rear seat assemblies.
  2.  
  3. Remove left and right front door scuff plates using a prytool.
  4.  
  5. Remove left and right rear door scuff plates using a prytool.
  6.  
  7. Remove right and left, front and rear door opening trim weather-stripping.
  8.  
  9. Remove back door weatherstrip
  10.  
  11. Remove right and left side center pillar garnish lower. Pull the garnish upward to remove it.
  12.  
  13. Remove the right and left side center pillar garnish, as follows:
    1. Remove the bolt and front seat outer belt shoulder anchor.
    2.  
    3. Using a prytool, remove the center pillar upper garnish.
    4.  

  14.  
  15. Remove tonneau cover assembly.
  16.  
  17. Remove deck board, as follows:
    1. Using a prytool, remove the 5 clips.
    2.  
    3. Remove the 2 bolts and deck side trim box.
    4.  

  18.  
  19. Remove the no. 2 and no. 3 deck boards.
  20.  
  21. Remove luggage compartment tray
  22.  
  23. Remove spare wheel cover tray
  24.  
  25. Remove the right and left side deck side trim boxes, as follows:
    1. Remove the screw.
    2.  
    3. Using a prytool, remove the deck trim box.
    4.  

  26.  
  27. Use a prytool to remove rear floor finish plate
  28.  
  29. Remove the right and left side deck trim side panels, as follows:
    1. Remove the 6 bolts.
    2.  
    3. Remove the bolt and rear seat outer belt floor anchor.
    4.  
    5. Remove the clip.
    6.  
    7. Using a prytool, remove the deck trim side panel.
    8.  

  30.  
  31. Remove the right and left side quarter pillar garnishes, as follows:
    1. Remove the clip.
    2.  
    3. Using a prytool, remove the quarter pillar garnish.
    4.  

  32.  
  33. Remove the right and left side roof side rail garnishes, as follows:
    1. Using a screwdriver, remove the roof side rail garnish.
    2.  

  34.  
  35. Remove the right and left side inner roof side garnish assemblies, as follows:
    1. Remove the clip.
    2.  
    3. Using a screwdriver, remove the roof side garnish assembly
    4.  

  36.  
  37. Use a prytool to remove the right and left front pillar garnishes.
  38.  
  39. Remove the 2 screws, then remove the visor assemblies.
  40.  
  41. Remove roof console box, as follows:
    1. Using a prytool, remove the courtesy lens.
    2.  
    3. Remove the 4 screws and roof console box inner cover.
    4.  

  42.  
  43. Remove room lamp no.1 using a prytool. Remove the 4 screws and room lamp, then disconnect the connector.
  44.  
  45. Remove the room lamp no.2
  46.  
  47. Remove the assist grip, as follows:
    1. Using a prytool, remove the assist grip plug.
    2.  
    3. Remove the 2 screws and assist grip.
    4.  

  48.  
  49. Remove visor holder. Remove the holder of the sun visor by turning it to the left.
  50.  
  51. Remove roof headlining assembly, as follows:
    1. Remove the 4 clips and roof headlining.
    2.  
    3. Remove the headlining assembly from the back door. If necessary, have an assistant help guide the headliner out from the vehicle.

      Click image to see an enlarged view

      Fig. Exploded view of the headlining and related components

    4.  

  52.  
  53. Using a prytool or screwdriver with its tip taped to prevent damage, remove the left and right sunroof side garnish.

    Click image to see an enlarged view

    Fig. Using a prytool or screwdriver with its tip taped to prevent damage, remove the left and right sunroof side garnish

  54.  
  55. Remove sunroof glass, as follows:
    1. Remove the 4 nuts.
    2.  
    3. Pull the sunroof glass upward to remove it.
    4.  

  56.  
  57. Using a prytool or screwdriver with its tip taped to prevent damage, remove the sunroof front garnish.

    Click image to see an enlarged view

    Fig. Using a prytool or screwdriver with its tip taped to prevent damage, remove the sunroof front garnish

  58.  
  59. Using a prytool or screwdriver with its tip taped to prevent damage, remove the sunroof rear garnish.

    Click image to see an enlarged view

    Fig. Using a prytool or screwdriver with its tip taped to prevent damage, remove the sunroof rear garnish

  60.  
  61. Remove sunroof drive gear (motor), as follows:
    1. Disconnect the clamp.
    2.  
    3. Remove the 2 bolts and drive gear (motor).
    4.  

  62.  
  63. Remove sunroof housing, as follows:
    1. Disconnect the 4 drain hoses from the housing.
    2.  
    3. Remove the 6 nuts and 6 bolts, then remove the housing as shown in the illustration.

      Click image to see an enlarged view

      Fig. Remove the 6 nuts and 6 bolts, then remove the housing as shown

    4.  

  64.  
  65. Remove roof wind deflector panel, as follows:
    1. Remove the 2 bolts and roof wind deflector panel.
    2.  

  66.  
  67. Remove sunshade trim, as follows:
    1. Remove the screw and stopper.
    2.  
    3. Remove the sunshade trim.
    4.  

  68.  
  69. Remove sunshade trim knob
  70.  
  71. Adjust fully closed position, as follows:
    1. Using a screwdriver with its tip taped to prevent damaging components, slide the drive cable of the sliding roof to align the matchmarks.

      Click image to see an enlarged view

      Fig. Adjust the fully closed position of the sunroof

    2.  

  72.  

To install:

  1. Install the sunroof housing and tighten the bolt to 68 inch lbs. (8.0 Nm) and the nut to 43 inch lbs. (5.0 Nm).
  2.  
  3. Install the sunroof drive gear (motor) and tighten the 2 bolts to 49 inch lbs. (5.4 Nm).
  4.  
  5. Install the sunroof glass and check for a difference between the sunroof (weatherstrip) and roof panel in level.
    1. Front end:

      0 + 1.0 mm (0 +/- 0.039 in.)
       
      0 - 2.0 mm (0 +/- 0.078 in.)
       

    2.  
    3. Rear end:

      0 + 2.0 mm (0 +/- 0.078 in.)
       
      0 - 1.0 mm (0 +/- 0.039 in.)
       

    4.  
    5. Corner of rear side:

      0 + 1.5 mm (0 + 0.059 in.)
       
      0 - 1.0 mm (0 - 0.039 in.)

      Click image to see an enlarged view

      Fig. Sunroof glass installation and level inspection

       

    6.  
    7. Adjust, as follows: Loosen the adjusting screw to adjust the sunroof panel, and tighten the screw at the point where the position of the sunroof panel is determined.

      Click image to see an enlarged view

      Fig. Loosen the adjusting screw to adjust the sunroof panel, and tighten the screw at the point where the position of the sunroof panel is determined

    8.  

  6.  
  7. Check for a difference between the sunroof (glass) and roof panel in level. Front end and rear end: 6.2 +/- 0.7 mm (0.264 +/- 0.028 in.).

    Click image to see an enlarged view

    Fig. Check for a difference between the sunroof (glass) and roof panel in level

    1. Adjust as follows: Loosen the adjusting screw to adjust the sunroof panel, and tighten the screw at the point where the position of the sunroof panel is determined.

      Click image to see an enlarged view

      Fig. Loosen the adjusting screw to adjust the sunroof panel, and tighten the screw at the point where the position of the sunroof panel is determined

    2.  

  8.  
  9. Check for leaks:
    1. When adjusting the sunroof, check there is no water leak.
    2.  
    3. If there is a water leak, readjust the sunroof.
    4.  

  10.  
  11. Install the headliner in the reverse of the removal procedure, noting the following steps:
    1. Align the markings, then install the wire harness with tape.
    2.  
    3. Install the roof headlining with the 4 clips.
    4.  
    5. Tighten the rear seat outer belt floor anchor bolt to 31 ft. lbs. (42 Nm).
    6.  
    7. Tighten the front seat outer belt shoulder anchor bolt to 31 ft. lbs. (42 Nm).
    8.  

  12.  

Highlander Hybrid

NOTE
This procedure requires removing the headlining assembly, which may require the help of an assistant.

  1. Remove rear seat assemblies.
  2.  
  3. Remove left and right front door scuff plates using a prytool.
  4.  
  5. Remove left and right rear door scuff plates using a prytool.
  6.  
  7. Remove right and left, front and rear door opening trim weather-stripping.
  8.  
  9. Remove back door weatherstrip
  10.  
  11. Remove right and left side center pillar garnish lower. Pull the garnish upward to remove it.
  12.  
  13. Remove the right and left side center pillar garnish, as follows:
    1. Remove the bolt and front seat outer belt shoulder anchor.
    2.  
    3. Using a prytool, remove the center pillar upper garnish.
    4.  

  14.  
  15. Remove tonneau cover assembly.
  16.  
  17. Remove deck board, as follows:
    1. Using a prytool, remove the 5 clips.
    2.  
    3. Remove the 2 bolts and deck side trim box.
    4.  

  18.  
  19. Remove the no. 2 and no. 3 deck boards.
  20.  
  21. Remove luggage compartment tray
  22.  
  23. Remove spare wheel cover tray
  24.  
  25. Remove the right and left side deck side trim boxes, as follows:
    1. Remove the screw.
    2.  
    3. Using a prytool, remove the deck trim box.
    4.  

  26.  
  27. Use a prytool to remove rear floor finish plate
  28.  
  29. Remove the right and left side deck trim side panels, as follows:
    1. Remove the 6 bolts.
    2.  
    3. Remove the bolt and rear seat outer belt floor anchor.
    4.  
    5. Remove the clip.
    6.  
    7. Using a prytool, remove the deck trim side panel.
    8.  

  30.  
  31. Remove the right and left side quarter pillar garnishes, as follows:
    1. Remove the clip.
    2.  
    3. Using a prytool, remove the quarter pillar garnish.
    4.  

  32.  
  33. Remove the right and left side roof side rail garnishes, as follows:
    1. Using a screwdriver, remove the roof side rail garnish.
    2.  

  34.  
  35. Remove the right and left side inner roof side garnish assemblies, as follows:
    1. Remove the clip.
    2.  
    3. Using a screwdriver, remove the roof side garnish assembly
    4.  

  36.  
  37. Use a prytool to remove the right and left front pillar garnishes.
  38.  
  39. Remove the 2 screws, then remove the visor assemblies.
  40.  
  41. Remove roof console box, as follows:
    1. Using a prytool, remove the courtesy lens.
    2.  
    3. Remove the 4 screws and roof console box inner cover.
    4.  

  42.  
  43. Remove room lamp no.1 using a prytool. Remove the 4 screws and room lamp, then disconnect the connector.
  44.  
  45. Remove the room lamp no.2
  46.  
  47. Remove the assist grip, as follows:
    1. Using a prytool, remove the assist grip plug.
    2.  
    3. Remove the 2 screws and assist grip.
    4.  

  48.  
  49. Remove visor holder. Remove the holder of the sun visor by turning it to the left.
  50.  
  51. Remove roof headlining assembly, as follows:
    1. Remove the 4 clips and roof headlining.
    2.  
    3. Remove the headlining assembly from the back door. If necessary, have an assistant help guide the headliner out from the vehicle.

      Click image to see an enlarged view

      Fig. Exploded view of the headlining and related components

    4.  

  52.  
  53. Using a prytool or screwdriver with its tip taped to prevent damage, remove the left and right sunroof side garnish.

    Click image to see an enlarged view

    Fig. Using a prytool or screwdriver with its tip taped to prevent damage, remove the left and right sunroof side garnish

  54.  
  55. Remove sunroof glass, as follows:
    1. Remove the 4 nuts.
    2.  
    3. Pull the sunroof glass upward to remove it.
    4.  

  56.  
  57. Using a prytool or screwdriver with its tip taped to prevent damage, remove the sunroof front garnish.

    Click image to see an enlarged view

    Fig. Using a prytool or screwdriver with its tip taped to prevent damage, remove the sunroof front garnish

  58.  
  59. Using a prytool or screwdriver with its tip taped to prevent damage, remove the sunroof rear garnish.

    Click image to see an enlarged view

    Fig. Using a prytool or screwdriver with its tip taped to prevent damage, remove the sunroof rear garnish

  60.  
  61. Remove sunroof drive gear (motor), as follows:
    1. Disconnect the clamp.
    2.  
    3. Remove the 2 bolts and drive gear (motor).
    4.  

  62.  
  63. Remove sunroof housing, as follows:
    1. Disconnect the 4 drain hoses from the housing.
    2.  
    3. Remove the 6 nuts and 6 bolts, then remove the housing as shown in the illustration.

      Click image to see an enlarged view

      Fig. Remove the 6 nuts and 6 bolts, then remove the housing as shown

    4.  

  64.  
  65. Remove roof wind deflector panel, as follows:
    1. Remove the 2 bolts and roof wind deflector panel.
    2.  

  66.  
  67. Remove sunshade trim, as follows:
    1. Remove the screw and stopper.
    2.  
    3. Remove the sunshade trim.
    4.  

  68.  
  69. Remove sunshade trim knob
  70.  
  71. Adjust fully closed position, as follows:
    1. Using a screwdriver with its tip taped to prevent damaging components, slide the drive cable of the sliding roof to align the matchmarks.

      Click image to see an enlarged view

      Fig. Adjust the fully closed position of the sunroof

    2.  

  72.  

To install:

  1. Install the sunroof housing and tighten the bolt to 68 inch lbs. (8.0 Nm) and the nut to 43 inch lbs. (5.0 Nm).
  2.  
  3. Install the sunroof drive gear (motor) and tighten the 2 bolts to 49 inch lbs. (5.4 Nm).
  4.  
  5. Install the sunroof glass and check for a difference between the sunroof (weatherstrip) and roof panel in level.
    1. Front end:

      0 + 1.0 mm (0 +/- 0.039 in.)
       
      0 - 2.0 mm (0 +/- 0.078 in.)
       

    2.  
    3. Rear end:

      0 + 2.0 mm (0 +/- 0.078 in.)
       
      0 - 1.0 mm (0 +/- 0.039 in.)
       

    4.  
    5. Corner of rear side:

      0 + 1.5 mm (0 + 0.059 in.)
       
      0 - 1.0 mm (0 - 0.039 in.)

      Click image to see an enlarged view

      Fig. Sunroof glass installation and level inspection

       

    6.  
    7. Adjust, as follows: Loosen the adjusting screw to adjust the sunroof panel, and tighten the screw at the point where the position of the sunroof panel is determined.

      Click image to see an enlarged view

      Fig. Loosen the adjusting screw to adjust the sunroof panel, and tighten the screw at the point where the position of the sunroof panel is determined

    8.  

  6.  
  7. Check for a difference between the sunroof (glass) and roof panel in level. Front end and rear end: 6.2 +/- 0.7 mm (0.264 +/- 0.028 in.).

    Click image to see an enlarged view

    Fig. Check for a difference between the sunroof (glass) and roof panel in level

    1. Adjust as follows: Loosen the adjusting screw to adjust the sunroof panel, and tighten the screw at the point where the position of the sunroof panel is determined.

      Click image to see an enlarged view

      Fig. Loosen the adjusting screw to adjust the sunroof panel, and tighten the screw at the point where the position of the sunroof panel is determined

    2.  

  8.  
  9. Check for leaks:
    1. When adjusting the sunroof, check there is no water leak.
    2.  
    3. If there is a water leak, readjust the sunroof.
    4.  

  10.  
  11. Install the headliner in the reverse of the removal procedure, noting the following steps:
    1. Align the markings, then install the wire harness with tape.
    2.  
    3. Install the roof headlining with the 4 clips.
    4.  
    5. Tighten the rear seat outer belt floor anchor bolt to 31 ft. lbs. (42 Nm).
    6.  
    7. Tighten the front seat outer belt shoulder anchor bolt to 31 ft. lbs. (42 Nm).
    8.  

  12.  
  13. If necessary, perform the initialization procedure, as outlined in the Chassis Electrical System.
  14.  

 
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