TOYOTA HIGHLANDER 2001 Service Repair Manual

05-778
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
968 Author
: Date
:
HINT:
If the VSC warning light does not blink, perform the zero point calibration again.
(g) Turn the ignition switch off.

05IU9-01
Turn igniton switch ON with AUTO
and R/F switches held down.
Indicator Check
DTC Check
(Sensor Check)
(continuous operation)
DTC Check
(Sensor Check)
(stepped operation)OFF
OFF
DEF
DEF
Actuator Check
(continuous operaiton)
DEFOFF
Actuator Check
(stepped operation)OFF
DEF
If both AUTO switch and R/F switches are
not pressed at the same time.
R/F
R/FR/F
AUTO
: Indicates a switch operation
AUTOAUTO
R/F: Recirculation/Fresh
Cancel check mode and start A/C control.
I30328
w/o Navigation System
I38758
w/ Navigation System
- DIAGNOSTICSAIR CONDITIONING SYSTEM
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
PRE-CHECK
1. LIST OF OPERATION METHODS
By operating each of the A/C control switches as shown in the diagram below, it is possible to enter the diag-
nosis check mode.
2. INDICATOR CHECK
(a) Turn the ignition switch ON while pressing the A/C control
AUTO switch and R/F switch simultaneously.

I41003
w/o Navigation System
I38757
w/ Navigation System
I36113
1 Sec.
1 Sec.
ON
OFF
I30327
DTC w/o Navigation System
I38759
w/ Navigation SystemDTC 05-1 118
- DIAGNOSTICSAIR CONDITIONING SYSTEM
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(b) Check that the indicators light up and go off at 1 second
intervals 4 times in succession.
HINT:

After the indicator check is completed, the system enters
the DTC automatically.

Press the OFF switch when desiring to cancel the check
mode.
3. DTC CHECK (SENSOR CHECK)
(a) Perform an indicator check. After the indicator check is
completed, the system enters the DTC check mode auto-
matically.
(b) Read the code displayed on the panel. Refer to the list of
codes on page 05- 1125 when reading the codes.
(Trouble codes are output at the temperature display.)

I30328
w/o Navigation System
I38758
w/ Navigation System
I30337
ECU-B Fuse Engine Room J/B
F46779
- DIAGNOSTICSAIR CONDITIONING SYSTEM
05-1 119
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) If the slower display is desired, press the FRONT DEF
switch and change it to stepped operation. Each time the
FRONT DEF switch is pressed, the display changes by 1
step.
4. CLEARING DTC
(a) To clear diagnostic trouble code, there are 2 ways.
(1) During sensor check, press the FRONT DEF switch
and REAR DEF switch at the same time.
(2) Pull the ECU-B fuse in engine room J/B for 20 sec.
or longer to clear the DTC memory.
5. DTC CHECK USING HAND-HELD TESTER
(a) Connect the hand-held tester to the DLC3.
(b) Power switch ON (ready).
(c) Read the DTC following the prompts on the tester screen.
Please refer to the hand-held tester operator's manual
for further details.
(d) Clear the DTCs.
HINT:
After repairing the malfunctions, clear the DTC.
(1) Connect the hand-held tester to DLC3.
(2) Turn the ignition switch to the ON position.
(3) Erase the DTCs following the prompts on the tester
screen.
HINT:
Refer to the hand-held tester operator's manual for further de-
tails.

I30329
w/o Navigation System
I38758
w/ Navigation System
Blower level Step No.Display
codeConditions
Air flow vent
Air inlet damper Magnetic clutch
ºCOOLº side
(Fully closed) Air mix damper
OFF FRESH FACE 0 1
2
3
4
6
7
8
9
10 4
51
17
17
17
17
17
17
17
31 0
1
2
3
6
7
8 4
5
9FACE
FACE
FACE
FACE
B/L
FOOT
FOOT
FOOT/ DEF
DEFFRESH
RECIRCULATION
RECIRCULATION
RECIRCULATION
RECIRCULATION
RECIRCULATION
RECIRCULATIONOFF
ON
ON
ON
ON
ON
ON
ON
ONºCOOLº side
(Fully closed)
ºCOOLº side
(Fully closed)
ºCOOLº side
(Fully closed)
ºCOOLº/ ºWARM º
(50% open)
ºCOOLº/ ºWARM º
(50% open)
ºWARMº side
(Fully opened)
ºWARMº side
(Fully opened)
ºWARMº side
(Fully opened) FRESH
FRESH
ºWARMº side
(Fully opened)
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
6. ACTUATOR CHECK
(a) Turn the ignition switch to the ON position while pressing
the A/C control AUTO switch and R/F (Recirculation /
Fresh) switch simultaneously.
(b) As each damper, motor and relay automatically operate
the actuator check at 1 second intervals from step No.1
to No.10 continuously, check the temperature and air flow
visually and by hand.
If a slower display is desired, press the temperature up switch
and change the display in the step operation. Each time the
temperature up switch is pressed, the display changes by 1
step.
HINT:

Codes are displayed from the smaller to the larger num-
bers in order.

To cancel the check mode, press the ºOFFº switch.

3 2 1 45678
9 1 0 111 21 31 41 51 6
DLC3
A04550
- DIAGNOSTICSAIR CONDITIONING SYSTEM
05-1 121
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
7. CHECK DLC3
(a) The vehicle's ECM uses ISO 9141-2 for communication.
The terminal arrangement of the DLC3 complies with
SAEJ1962 and matches the ISO 9141-2 format.
Terminal No.Connection/Voltage or ResistanceCondition
7Bus + Line/Pulse generationDuring transmission
4Chassis Ground - Body Ground/1 W or lessAlways
5Signal Ground - Body Ground/1 W or lessAlways
16Battery Positive - Body Ground/9 to 14 VAlways
8. DATA LIST
HINT:
From the DATA LIST displayed on the hand-held tester, you can read the values of the displays, sensors,
actuators and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is
one way to shorten labor time.
(a) Connect the hand-held tester to the DLC3.
(b) Turn the ignition switch to the ON position.
(c) From the display on the tester, select the ºDATA LISTº.
ALL:
ItemMeasurement Item / Display
(Range)Normal ConditionDiagnostic Note
A/C SIGA/C signal / ON or OFFA/C ON: ON-
A C:
ItemMeasurement Item/Display
(Range)Normal ConditionDiagnostic Note
ROOM TEMP
Room temperature sensor
/min.: -6.5C (20.3F)
max.: 57.25C (135.05F)
Actual room temperature-
AMBI TEMP SENS
Ambient temperature sensor
/min.: -23.3C (-9.94F)
max.: 65.95C (150.71F)
Actual ambient temperature-
AMBI TEMP
Adjusted ambient temperature
/min.: -30.8C (-23.44F)
max.: 50.8C (123.44F)
Actual ambient temperature-
EVAP TEMP
Evaporator temperature sensor
/min.: -29.7C (-21.46F)
max.: 59.55C (139.19F)
Actual evaporator temperature-
SOLAR SENS-DSolar sensor (Driver side)
/min.: 0 max.: 255Changes depending on brightness
(Driver side)-
COOLANT TEMP
Engine coolant temperature
/min.: 1.3C (34.34F)
max.: 90.55C (194.99F)
Actual engine coolant temperature-
SET TEMP-D
Set temperature
(Driver side)
/min.: 0 max.: 255Actual set temperature
(Driver side)-
A/M DAMP POS-D
Air mix damper position
(Driver side)
/min.: -14% max.: 113.5%Changes depending on the set
temperature (Driver side)-

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- DIAGNOSTICSAIR CONDITIONING SYSTEM
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)ItemDiagnostic Note Normal Condition Measurement Item/Display
(Range)
A/O DAMP POSAir outlet damper position
/min.: -14% max.: 113.5%Changes depending on air outlet
power position-
A/M DAMP TARG-D
Air mix damper target position
(Driver side)
/min.: -14% max.: 113.5%Changes depending on the set
temperature (Driver side)-
A/O DAMP TARGAir outlet damper target position
/min.: -14% max.: 113.5%Changes depending on air outlet
power position-
BLOWER LEVELBlower motor speed level
/min.: Level 0 max.: Level 31Changes depending on blower lev-
el-
#CODESNumber of Trouble Codes
/min.: 0 max.: 255--
HAND FREE TELHands free telephone / OFF, ON--
SET TEMP SHIFTShift set temperature/2C decr, 1C
decr, NORMAL, 1C incr, 2C incrChanges depending on shift set
temperature *1-
COMPRESSOR MODECompressor mode
/AUTO, MANUALChanges depending on compres-
sor mode *1-
COMPRS/DEF OPERCompressor/DEF operation mode
/LINK, NORMALChanges depending on compres-
sor/DEF operation mode *1-
HINT:
*1: It differs depending on the user setting.

F10007
F10008A
F10009A
F10010
Cutting Okay
Reinforcement
Corners
WRONG
INTRODUCTIONIN-10
PROPER AND EFFICIENT WORK
PROCEDURES
1. REMOVAL
(a) PRE-REMOVAL MEASURING
(1) Before removal or cutting operations, take measure-
ments in accordance with the dimension diagram. Al-
ways use a puller to straighten a damaged body or
frame.
(b) CUTTING AREA
(1) Always cut in a straight line and avoid reinforced area.
(c) PRECAUTIONS FOR DRILLING OR CUTTING
(1) Check behind any area to be drilled or cut to insure
that there are no hoses, wires, etc., that may be dam-
aged.
HINT: See Handling Precautions on Related Compo-
nentsº on page IN-15.
(d) REMOVAL OF ADJACENT COMPONENTS
(1) When removing adjacent components, apply protec-
tive tape to the surrounding body and your tools to pre-
vent damage.
HINT: See Handling Precautions on Related Compo-
nentsº on page IN-15.

F10011A
F10012
F10013A
F10014
F10015A
Less than
3mm
Puncher
Air SawOverlap
20
30mm
INTRODUCTIONIN-11
2. PREPARATION FOR INSTALLATION
(a) SPOT WELD POINTS
(1) When welding panels with a combined thickness of
over 3mm (0.12in.), use a MIG (Metal Inert Gas) weld-
er for plug welding.
HINT: Spot welding will not provide sufficient durability
for panels over 3mm (0.12in.) thick.
(b) APPLICATION OF WELD-THROUGH PRIMER
(SPOT SEALER)
(1) Remove the paint from the portion of the new parts
and body to be welded, and apply weld-through prim-
er.
(c) MAKING HOLES FOR PLUG WELDING
(1) For areas where a spot welder cannot be used, use a
puncher or drill to make holes for plug welding.
REFERENCE:mm (in.)
Thickness of welded portionSize of plug hole
1.0 (0.04) under5 (0.20) ù over
1.0 (0.04) - 1.5 (0.06)6.4 (0.25) ù over
1.5 (0.06) over8 (0.31) ù over
(d) SAFETY PRECAUTIONS FOR ELECTRICAL COM-
PONENTS
(1) When welding, there is a danger that electrical compo-
nents will be damaged by the electrical current flowing
through the body.
(2) Before starting work, disconnect the negative terminal
of the battery and ground the welder near the welding
location of the body.
(e) ROUGH CUTTING OF JOINTS
(1) For joint areas, rough cut the new parts, leaving 20 -
30mm (0.79 - 1.18in.) overlap.

F10016A
F10017A
F10018A
F10019A
F10020A
Body
Measurement
Diagrams
WRONG
CORRECT WRONG
Tip Cutter
Old
Spot
LocationsNew Spot
Locations
INTRODUCTIONIN-12
3. INSTALLATION
(a) PRE-WELDING MEASUREMENTS
(1) Always take measurements before installing under-
body or engine components to insure correct assem-
bly. After installation, confirm proper fit.
(b) WELDING PRECAUTIONS
(1) The number of welding spots should be as follows.
Spot weld: 1.3 X No. of manufacturer's spots.
Plug weld: More than No. of manufacturer's plugs.
(2) Plug welding should be done with a MIG (Metal Inert
Gas) welder. Do not gas weld or braze panels at areas
other than specified.
(c) POST-WELDING REFINISHING
(1) Always check the welded spots to insure they are se-
cure.
(2) When smoothing out the weld spots with a disc grind-
er, be careful not to grind off too much as this would
weaken the weld.
(d) SPOT WELD LOCATIONS
(1) Try to avoid welding over previous spots.
(e) SPOT WELDING PRECAUTIONS
(1) The shape of the welding tip point has an effect on the
strength of the weld.
(2) Always insure that the seams and welding tip are free
of paint.