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2008 Toyota Highlander Hybrid Limited – Airbag Light With B1650 and B1794
CUSTOMER CONCERN The airbag warning light is on with DTCs B1650 and B1794 stored. CAUSE Power and circuit testing at the occupant-classification ECU confirmed a failed connection at the DN3 junction connector. CORRECTION Repair the terminals and connections at the DN3 junction connector.
2008 Toyota Highlander Hybrid Limited – No Brake Pressure After Rear Calipers
CUSTOMER CONCERN Customer states brake pressure was lost at the right rear after rear brake and caliper replacement, and manual, gravity and pressure bleeding did not restore the pedal. CAUSE Air remained trapped in the electronically controlled hydraulic brake system, and zero accumulator pressure prevented the scan-tool bleed routine from operating normally. CORRECTION Operate brake pump to establish accumulator pressure, then perform complete hybrid ABS service-bleed proce
2008 Toyota Highlander Hybrid Limited – No Crank and No Electrical Power
CUSTOMER CONCERN Customer states the vehicle will not crank or start and nearly all electrical systems are inoperative after the 12-volt battery went dead. CAUSE Voltage testing found no power at the engine-compartment battery terminal, confirming the 120-amp DC/DC fusible link was open. CORRECTION Remove and replace 120-amp DC/DC fusible link. Inspect remaining power-distribution fuses and verify normal vehicle power-up and READY-mode operation.
2008 Toyota Highlander Hybrid Limited – Noise When Powered On
CUSTOMER CONCERN Customer states a noise begins in the engine compartment as soon as the vehicle is powered on. CAUSE Inspection isolated the noise to the auxiliary heater water pump, one of the components operating immediately at power-up. CORRECTION Remove and replace auxiliary heater water pump. Refill and bleed the heater-coolant circuit and verify quiet pump operation.
2008 Toyota Highlander Hybrid Limited – C1203 C1345 After Battery Went Dead
CUSTOMER CONCERN Customer states the 12-volt battery went dead during an alignment and DTCs C1203 and C1345 are now stored. CAUSE Loss of battery voltage erased the linear-solenoid valve offset calibration, leaving the brake-control system incorrectly configured. CORRECTION Perform linear-solenoid valve initialization and calibration, complete yaw-rate sensor calibration as required, clear DTCs C1203 and C1345 and verify brake-system operation.
2008 Toyota Highlander Hybrid Limited – Intermittent Shutdown With P0A40
CUSTOMER CONCERN Customer states the vehicle intermittently shuts off and all warning lights illuminate. DTC P0A40 is stored. CAUSE Drive-motor position-sensor circuit testing and inverter recall identification confirmed an internal hybrid converter/inverter assembly failure. CORRECTION Remove and replace hybrid converter/inverter assembly. Complete applicable recall programming, clear hybrid-system DTCs and verify vehicle operation.
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