TOYOTA HIGHLANDER 2001 Service Repair Manual

010QP-01
01-46
- INTRODUCTIONTERMS
46 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )--ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal-
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection-
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position-
CTOXContinuous Trap Oxidizer-
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel InjectionDirect Injection (DI/INJ)
DIDistributor Ignition-
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Trouble Code
DTMDiagnostic Test Mode-
ECLEngine Coolant Level-
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionDistributorless Ignition (DLI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control-
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory-
FEPROMFlash Erasable Programmable Read Only Memory-
FFFlexible Fuel-
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)

- INTRODUCTIONTERMS
01-47
47 Author
: Date
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2005 HIGHLANDER REPAIR MANUAL (RM1144U) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module-
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel-Shutoff-
ISCIdle Speed Control-
KSKnock SensorKnock Sensor
MAFMass AirflowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure-
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface Temperature-
MVZManifold Vacuum Zone-
NVRAMNon-V olatile Random Access Memory-
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn-Board DiagnosticOn-Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OLOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module-
PNPPark/Neutral Position-
PROMProgrammable Read Only Memory-
PSPPower Steering Pressure-
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module-
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE-ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter-
SRIService Reminder Indicator-
SRTSystem Readiness Test-
STScan Tool-
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter

01-48
- INTRODUCTIONTERMS
48 Author
: Date
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2005 HIGHLANDER REPAIR MANUAL (RM1144U) TCM
Transmission Control ModuleTransmission ECU, ECT ECU
TPThrottle PositionThrottle Position
TRTransmission Range-
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree-W ay Catalytic Converter
Three-W ay Catalytic (TWC)
Manifold Converter
CC
RO
TWC+OCThree-W ay + Oxidation Catalytic ConverterCCR + CCo
VA FVolume AirflowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor
WOTWide Open ThrottleFull Throttle
WU-OCWarm Up Oxidation Catalytic Converter-
WU-TWCWarm Up Three-Way Catalytic Converter-
3GRThird Gear-
4GRFourth Gear-

010QM-01
01-26- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
26 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
HOW TO PROCEED WITH TROUBLESHOOTING
HINT:
Carry out troubleshooting in accordance with the procedures below. Only a basic procedure is shown. De-
tails in the Diagnostic Section show the most effective methods for each circuit. Confirm the troubleshooting
procedures for the relevant circuit before beginning troubleshooting.
1 VEHICLE BROUGHT TO WORKSHOP
2 CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
3 SYMPTOM CONFIRMATION AND DTC (AND FREEZE FRAME DATA) CHECK
(a) Check the battery positive voltage.
Standard: 11 to 14 V (Engine stopped)
(b) Visually check the wire harness, connectors and fuses for open and short, etc.
(c) Warm up the engine to the normal operating temperature.
(d) Confirm the problem symptoms and conditions, and check for DTCs according to the related chart.
OK Go to step 5
NG
4 DTC CHART
(a) Check the results obtained in step 3, then confirm the inspection procedures for the system or part
using the DTC chart.
Go to step 6
5 PROBLEM SYMPTOMS CHART
(a) Check the results obtained in step 3. Confirm the inspection procedures for the system or part using
the problem symptoms table.
6 CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Confirm the circuit in the system or the part that should be checked using the problem symptoms table
or the results obtained in step 4.

- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01-27
27 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
7 REPAIR
(a) Repair the affected system or part according to the instructions in step 6.
8 CONFIRMATION TEST
(a) After completing repairs, confirm that the problem has been solved. If the problem does not recur, per-
form a confirmation test under the same conditions and in the same environment as when it occurred
the first time.
END

Important Points with Customer Problem Analysis

What ----- Vehicle model, system name

When ----- Date, time, occurrence frequency

Where ----- Road conditions

Under what conditions? ----- Running conditions, driving conditions, weather conditions

How did it happen? ----- Problem symptoms
(Sample) Supplemental Restraint System check sheet.
Supplemental Restraint System Check Sheet
Customer's Name
Date Vehicle Brought In
VIN
Licence Plate No.
Odometer Reading
km
miles
Date Problem First Occurred
Weather
Temperature
Vehicle OperationFine Cloudy
StartingIdling
Driving
Constant speedAcceleration
OtherInspector's
Name
CUSTOMER PROBLEM ANALYSIS CHECK
Production Date
RainySnowyOther / / / /
/ /
Approx.
Deceleration [
]
01-28- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
28 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
CUSTOMER PROBLEM ANALYSIS
HINT:
In troubleshooting, the problem symptoms must be confirmed accurately. Preconceptions should be
discarded in order to give an accurate judgement. To clearly understand what the problem symptoms
are, it is extremely important to ask the customer about the problem and the conditions at the time it
occurred.
As much information as possible should be gathered for reference. Past problems that seem unrelated
may also help in some cases. In the Diagnostic section, a customer problem analysis table is provided
for each system.
5 items are important points in the problem analysis:

- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01-29
29 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT:
The diagnostic system in the HIGHLANDER has various functions.
The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous
malfunction's DTC can be checked by a technician during troubleshooting.
Another function is the Input Signal Check, which checks if the signals from various switches are sent
to the ECU correctly.
By using these functions, the problem areas can be narrowed down and troubleshooting is more effec-
tive. Diagnostic functions are incorporated in the following systems in the HIGHLANDER:
SystemDiagnostic Trouble
Code CheckInput Signal Check
(Sensor Check)Diagnotis Test Mode
(Active Test)
SFI System
(with Check Mode)
ABS with EBD & BA & TRAC & VSC System
Electronic Controlled Automatic Transaxle [ECT]
(with Check Mode)
Air Conditioning System
Supplement Restraint System
Power Window Control System
Power Door Lock Control System
Wireless Door Lock Control System
Engine Immobiliser System
Multiplex Communication System
Cruise Control System
In the DTC check, it is very important to determine whether the problem indicated by the DTC is: 1 still
occurring, or 2 occurred in the past but has since returned to normal. In addition, the DTC should be
compared to the problem symptom to see if they are related. For this reason, DTCs should be checked
before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine
current conditions, as shown in the table below.
Never skip the DTC check. Failure to check DTCs may, depending on the case, result in unnecessary
troubleshooting for systems operating normally or lead to repairs not pertinent to the problem. Follow
the procedures listed above in the correct order.
A flow chart showing how to proceed with troubleshooting using the DTC check is shown below. Direc-
tions from the flow chart will indicate should be performed DTC troubleshooting or to the troubleshoot-
ing of each problem symptom.
1 DTC CHECK
2 MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR THE MEMORY
3 SYMPTOM CONFIRMATION
aSymptoms exist
bNo symptoms exist
a Go to step 5

01-30- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
30 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
b
4 SIMULATION TEST USING THE SYMPTOM SIMULATION METHODS
5 DTC CHECK
aDTC displayed
bNo DTC displayed
a Troubleshooting of problem indicated by DTC
b
6 SYMPTOM CONFIRMATION
aNo symptoms exist
bSymptoms exist
If a DTC was displayed in the initial DTC check, it indicates that
the trouble may have occurred in a wire harness or connector
in that circuit in the past. Check the wire harness and connec-
tors (see page 01-36).
a SYSTEM NORMAL
b
TROUBLESHOOTING OF EACH PROBLEM SYMPTOM
The problem is still occurring in a place other than the diagnostic circuit (the DTC displayed first is either for
a past problem or a secondary problem).

B71602
Vibrate Slightly
Shake Slightly
Vibrate
Slightly
D25084
Malfunction
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01-31
31 Author
: Date
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
SYMPTOM SIMULATION
HINT:
The most difficult case in troubleshooting is when no problem symptoms occur. In such cases, a thorough
customer problem analysis must be carried out. A simulation of the same or similar conditions and environ-
ment in which the problem occurred in the customer's vehicle should be carried out. No matter how much
skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to
important repairs being overlooked and mistakes or delays.
For example:
With a problem that only occurs when the engine is cold or occurs as a result of vibration caused by the road
during driving, the problem can never be determined if the symptoms are being checked on a stationary ve-
hicle or a vehicle with a warmed-up engine.
Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below
are effective substitutes for the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must be con-
firmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester
and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal.
Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system
to narrow down the possible causes.
1. VIBRATION METHOD: When vibration seems to be
the major cause.
(a) PART AND SENSOR
(1) Apply slight vibration with a finger to the part of the
sensor considered to be the cause of the problem
and check whether or not the malfunction occurs.
HINT:
Applying strong vibration to relays may open relays.
(b) CONNECTORS
(1) Slightly shake the connector vertically and horizon-
tally.
(c) WIRE HARNESS
(1) Slightly shake the wire harness vertically and hori-
zontally.
The connector joint and fulcrum of the vibration are
the major areas that should be checked thoroughly.
2. HEAT METHOD: If the problem seems to occur when
the area in question is heated.
(a) Heat the component that is the possible cause of the mal-
function with a hair dryer or similar device. Check if the
malfunction occurs.
NOTICE:
Do not heat to more than 60C (140F). Exceeding this
temperature may damage components.
Do not apply heat directly to the parts in the ECU.

D25085
B02389
ON 01-32
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
32 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
3. WATER SPRINKLING METHOD: When the malfunc-
tion seems to occur on a rainy day or in highhumidity.
(a) Sprinkle water onto the vehicle and check if the malfunc-
tion occurs.
NOTICE:
Never sprinkle water directly into the engine compart-
ment. Indirectly change the temperature and humid-
ity by applying water spray onto the front of the radia-
tor.
Never apply water directly onto electronic compo-
nents.
HINT:
If the vehicle has or had a water leakage problem, the leakage
may have damaged the ECU or connections. Look for evidence
of corrosion or shorts. Proceed with caution during water tests.
4. HIGH ELECTRICAL LOAD METHOD: When a malfunc-
tion seems to occur when electrical load is exces-
sive.
(a) Turn on all the electrical loads including the heater blower,
headlights, rear window defogger, etc., and check if the
malfunction occurs.