TOYOTA HIGHLANDER 2001 Service Repair Manual

051ZF-14
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-5
195 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
HOW TO PROCEED WITH TROUBLESHOOTING
The hand-held tester is used in steps 3, 4, 5, 7 and 10.
1 VEHICLE BROUGHT TO WORKSHOP
NEXT
2 CUSTOMER PROBLEM ANALYSIS (See page 05-8)
NEXT
3 CONNECT HAND-HELD TESTER TO DLC3
HINT:
If the display indicates a communication fault in the tool, inspect the DLC3.
NEXT
4 CHECK DTC AND FREEZE FRAME DATA (See page 05-38)
HINT:
Record or print DTC and freeze frame data, if needed.
NEXT
5 CLEAR DTC AND FREEZE FRAME DATA (See page 05-38)
NEXT
6 VISUAL INSPECTION
NEXT
7 SETTING CHECK (TEST) MODE DIAGNOSIS (See page 05-40)
NEXT
8 PROBLEM SYMPTOM CONFIRMATION
HINT:
If the engine does not start, perform steps 10 and 12 first.
Malfunction does not occurA
Malfunction occursB
B Go to step 10
A

05-6
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
196 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
9 SYMPTOM SIMULATION
NEXT
10 DTC CHECK (See page 05-38)
Malfunction codeA
No codeB
B Go to step 12
A
11 DTC CHART (See page 05-48)
NEXT
Go to step 14
12 BASIC INSPECTION (See page 05-10)
Wrong parts not confirmedA
Wrong parts confirmedB
B Go to step 17
A
13 PROBLEM SYMPTOMS TABLE (See page 05-31)
Wrong circuit confirmedA
Wrong parts confirmedB
B Go to step 17
A
14 CHECK ECM POWER SOURCE CIRCUIT (See page 05-312)
NEXT
15 CIRCUIT INSPECTION
Malfunction not confirmedA
Malfunction confirmedB
B Go to step 18
A

- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-7
197 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
16 CHECK FOR INTERMITTENT PROBLEMS (See page 05-9)
NEXT
Go to step 18
17 PARTS INSPECTION
NEXT
18 IDENTIFICATION OF PROBLEM
NEXT
19 ADJUSTMENT, REPAIR
NEXT
20 CONFIRMATION TEST
NEXT
END

B78737
O5
740EE-01
74-8
- SLIDING ROOF/CONVERTIBLESLIDING ROOF SYSTEM
3711 Author
: Date
:
INSPECTION
1. INSPECT SLIDING ROOF SWITCH ASSY
(a) Disconnect the sliding roof switch connector, and check
the voltage or continuity of each terminal of the connector.
Standard
Symbols (Terminal No.)Wiring colorConditionSpecified condition
UP (O5 - 6) @ Body groundG @ -Each switch OFFContinuity
DOWN (O5 - 4) @ Body groundW @ -Each switch OFFContinuity
UP (O5 - 6) @ Body groundG @ -

Ignition switch ON

Sliding roof fully closed

Slide open switch OFF " ON
(Slide open side)
0 V " 10 to 14 V
DOWN (O5 - 4) @ Body groundW @ -

Ignition switch ON

Sliding roof fully closed

Slide open switch OFF " ON
(Slide open side)
0 V " 10 to 14 V
IG (O5 - 9) @ Body groundGR @ -Ignition switch ON0 V " 10 to 14 V
GND (O5 - 1) @ Body groundW - B @ -ConstantContinuity

141P0-02
A87787
CORRECTINCORRECT
A80020
Hand-held Tester
DLC3
A82779
7 6 5 34 2 18
9 10111213141516DLC3
CG
TC
- ENGINE MECHANICALENGINE (2AZ-FE)
14-1
2494 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
ENGINE (2AZ-FE)
INSPECTION
1. INSPECT ENGINE COOLANT (See page 16-6)
2. INSPECT ENGINE OIL
3. INSPECT BATTERY
4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSY
5. INSPECT SPARK PLUG (See page 18-3)
6. INSPECT V-RIBBED BELT
HINT:

After installing the drive belt, check that it fits properly in
the ribbed grooves. Check with your hand to confirm that
the belt has not slipped out of the groove on the bottom
of the crank pulley.

ºNew beltº is a belt which has been used less than 5 min-
utes on a running engine.

ºUsed beltº is a belt which has been used on a running en-
gine for 5 minutes or more.

After installing a new belt, run the engine for approximate-
ly 5 minutes and then recheck the tension.
7. INSPECT IGNITION TIMING
(a) Warm up the engine.
(b) When using the hand-held tester:
Check the ignition timing.
(1) Connect the hand-held tester to the DLC3.
(2) Enter DATA LIST MODE on the hand-held tester.
Ignition timing: 8 to 12 BTDC @ idle
HINT:
Please refer to the hand-held tester operator's manual for help
on selecting the DATA LIST.
(c) When not using the hand-held tester:
Check the ignition timing.
(1) Using SST, connect terminals 13 (TC) and 4 (CG)
of the DLC3.
SST 09843-18040
NOTICE:

Confirm the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn off all electrical systems before connecting the
terminals.

Perform this inspection after the cooling fan motor is
turned off.

A52004
A80020
Hand-held Tester
DLC3
A82779
7 6 5 34 2 18
9 10111213141516DLC3
TA C
14-2
- ENGINE MECHANICALENGINE (2AZ-FE)
2495 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(2) Remove the cylinder head cover No. 2.
(3) Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which can detect the first signal.

After checking, be sure to tape the wire harness.
(4) Check the ignition timing at idle.
Ignition timing: 8 to 12 BTDC @ idle
NOTICE:
When checking the ignition timing, the transmission
should be in the neutral position.
HINT:
After engine rpm is kept at 1,000 to 1,300 rpm for 5 seconds,
check that it returns to idle speed.
(5) Remove the SST from the DLC3.
SST 09843-18040
(6) Check the ignition timing at idle.
Ignition timing: 5 to 15 BTDC @ idle
(7) Confirm that ignition timing moves to the advanced
angle side when the engine rpm is increased.
(8) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up the engine.
(b) When using the hand-held tester:
Check the idle speed.
(1) Connect the hand-held tester to the DLC3.
HINT:
Please refer to the hand-held tester operator's manual for fur-
ther details.
(2) Enter DATA LIST MODE on the hand-held tester.
Idle speed: 610 to 710 rpm
NOTICE:

When checking the idle speed, the transmission
should be in the neutral position.

Check idle speed with the cooling fan off.

Switch off all accessories and air conditioning before
connecting the hand-held tester.
(c) When not using the hand-held tester:
Check the idle speed.
(1) Using SST, connect tachometer tester probe to ter-
minal 9 (TAC) of the DLC3.
(2) Check the idle speed.
Idle speed: 610 to 710 rpm
SST 09843-18030

A01037
- ENGINE MECHANICALENGINE (2AZ-FE)
14-3
2496 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the ignition coils.
(d) Remove the spark plugs.
(e) Check the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug
hole.
(2) Fully open the throttle.
(3) While cranking the engine, measure the compres-
sion pressure.
Compression pressure:
1,360 kPa (13.9 kgf/cm
2, 198 psi)
Minimum pressure: 0.98 MPa (10 kgf/cm
2, 142 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 14 psi)
NOTICE:

Always use a fully charged battery to obtain engine
speed of 250 rpm or more.

Check other cylinder's compression pressure in the
same way.

This measurement must be done as quickly as pos-
sible.
(4) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through the
spark plug hole and inspect again.
HINT:

If adding oil increases the compression, the piston rings
and/or cylinder bore may be worn or damaged.

If pressure stays low, a valve may be stuck or seated im-
properly, or there may be leakage in the gasket.
10. INSPECT CO/HC
(a) Start the engine.
(b) Rev the engine at 2,500 rpm for approximately 180 seconds.
(c) Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.
(d) Immediately check CO/HC concentration at idle and/or 2,500 rpm.
HINT:

Complete the measuring within 3 minutes.

Check regulations and restrictions in your area when performing 2 mode CO/HC concentration testing
(engine check at both idle speed and at 2,500 rpm).
(e) If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.
(1) Check A/F sensor operation (see page 12-3).
(2) See the table below for possible causes, and then inspect and repair.

14-4
- ENGINE MECHANICALENGINE (2AZ-FE)
2497 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)CO
HCProblemsCauses
NormalHighRough idle
1. Faulty ignitions:

Incorrect timing

Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaky intake and exhaust valves
4. Leaky cylinders
LowHighRough idle
(fluctuating HC reading)
1. Vacuum leaks:

PCV hoses

Intake manifold

Throttle body

Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(black smoke from exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI system:

Faulty pressure regulator

Defective ECT

Defective MAF meter

Faulty ECM

Faulty injectors

Faulty throttle position sensor

'05 HIGHLANDER_U (L/O 0409)
ii
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
Important information about this manual
Safety and vehicle damage warnings
Throughout this manual, you will see safety and vehicle dam-
age warnings. You must follow these warnings carefully to
avoid possible injury or damage.
The types of warnings, what they look like, and how they are
used in this manual are explained as follows:
CAUTION
This is a warning against anything which may cause
injury to people if the warning is ignored. You are
informed about what you must or must not do in
order to reduce the risk of injury to yourself and
others.
NOTICE
This is a warning against anything which may cause
damage to the vehicle or its equipment if the warning
is ignored. You are informed about what you must or
must not do in order to avoid or reduce the risk of
damage to your vehicle and its equipment.
Safety symbol
When you see the safety symbol
shown above, it means: Do not...º;
Do not do thisº; or Do not let this
happenº.

'05 HIGHLANDER_U (L/O 0409)
iii
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
Important information about your Toyota
Occupant restraint systems
Toyota encourages you and your family to take the time to
read Section 1- 3 of this Owner 's Manual carefully. In
terms of helping you understand how you can receive the
maximum benefit of the occupant restraint systems this
vehicle provides, Section 1- 3 of this Owner 's Manual is
the most important Section for you and your family to
read.
Section 1- 3 describes the function and operation concern-
ing seats, seat belts, SRS airbags and child restraint sys-
tems of this vehicle and some potential hazards you
should be aware of. These systems work together along
with the overall structure of this vehicle in order to provide
occupant restraint in the event of a crash. The effect of
each system can be enhanced when it is used properly
and together with other systems. No single occupant re-
straint system can, by itself, provide you or your family
with the equal level of restraint which these systems can
provide when used together. That is why it is important for
you and your family to understand the purpose and proper
use of each of these systems and how they relate to each
other.
The purpose of all occupant restraint systems is to help
reduce the possibility of death or serious injury in the
event of a collision. None of these systems, either individ-
ually or together, can ensure that there is no injury in the
event of collision. However, the more you know about
these systems and how to use them properly, the greater
your chances become of surviving an accident without
death or serious injury.
Seat belts provide the primary restraint to all occupants of
the vehicle, and every occupant of the vehicle should wear
seat belts properly at all times. Children should always be
secured in child restraint systems that are appropriate for
their age and size. SRS (Supplemental Restraint System)
airbags are, as their names imply, designed to work with,
and be supplemental to, seat belts and are not substitutes
for them. SRS airbags can be very effective in reducing
the risk of head and chest injuries by preventing contact of
the head and chest with interior portions of the vehicle.