TOYOTA HIGHLANDER 2001 Service Repair Manual

F10021A
F10022
F10023
Sealer Gun
INTRODUCTIONIN-13
4. ANTI-RUST TREATMENT
(a) BODY SEALER APPLICATION
(1) For water-proofing and anti-corrosion measures, al-
ways apply the body sealer to the body panel seams
and hems of the doors, hoods, etc.
(b) UNDERCOAT APPLICATION
(1) To prevent corrosion and protect the body from dam-
age by flying stones, always apply sufficient under-
coat to the bottom surface of the under body and in-
side of the wheel housings.
5. ANTI-RUST TREATMENT AFTER PAINTING
PROCESS
(a) ANTI-RUST AGENT (WAX) APPLICATION
(1) To preserve impossible to paint areas from corrosion,
always apply sufficient anti-rust agent (wax) to the in-
side of the hemming areas of the doors and hoods,
and around the hinges, or the welded surfaces inside
the boxed cross-section structure of the side member,
body pillar, etc.

F10024A

Apply the anti-chipping paint after
the top coat.
Apply the anti-chipping paint before
the second coat.
Anti-Chipping Paint
Top Coat
Second Coat
Under Coat (ED Primer)
Steel MetalTop Coat
Second Coat
Anti-Chipping Paint
Under Coat (ED Primer)
Steel Metal
INTRODUCTIONIN-14
6. ANTI-RUST TREATMENT BY PAINTING
REFERENCE:
Painting prevents corrosion and protect the sheet
metal from damage. In this section, anti-chipping paint
only for anti-corrosion purpose is described.
(a) ANTI-CHIPPING PAINT
(1) To prevent corrosion and protect the body from dam-
age by flying stones, etc., apply anti-chipping paint to
the rocker panel, wheel arch areas, balance panel,
etc.
HINT:
Depending on the model or the application area, there
are cases where the application of anti-chipping paint
is necessary before the second coat or after the top
coat.

05CD2-13
05-786
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
976 Author
: Date
:
PROBLEM SYMPTOMS TABLE
If there are no DTCs output but the problem still occurs, check the circuits for each problem symptom in the
order given in the table below and proceed to the relevant troubleshooting page.
NOTICE:
When replacing the skid control ECU, sensor, etc., turn the ignition switch off.
SymptomsSuspected AreasSee page
ABS does not operate
BA does not operate
EBD does not operate
1. Check the DTC again and make sure that the normal
code is output.
2. IG power source circuit and ground circuit.
3. Speed sensor circuit
4. Check the ABS & TRAC actuator with a hand-held tes-
ter.
If abnormal, check the hydraulic circuit for leakage.
5. If the symptoms still occur even after the above circuits
in suspected areas are inspected and proved to be
normal, replace the skid control ECU.05-765
05-827
05-788
05-795
32-36
ABS does not operate efficiently
BA does not operate efficiently
EBD does not operate efficiently
1. Check the DTC again and make sure that the normal
code is output.
2. Speed sensor circuit
3. Stop lamp switch circuit
4. Check the ABS & TRAC actuator with a hand-held tes-
ter.
If abnormal, check the hydraulic circuit for leakage.
5. If the symptoms still occur even after the above circuits
in suspected areas are inspected and proved to be
normal, replace the skid control ECU.05-765
05-788
05-795
32-36
ABS warning light abnormal Remain ON1. ABS warning light circuit
2. Skid control ECU05-840
-
ABS warning light abnormal Does not light up1. ABS warning light circuit
2. Skid control ECU05-844
-
DTC of ABS check cannot be done
1. Check the DTC again and make sure that the normal
code is output.
2. TC terminal circuit
3. If the symptoms still occur even after the above circuits
in suspected areas are inspected and proved to be
normal, replace the skid control ECU.05-765
05-868
Sensor signal check cannot be done1. TS terminal circuit
2. Skid control ECU05-873
-
VSC and/or TRAC does not operate
1. Check the DTC again and make sure that the normal
code is output.
2. IG power source circuit and ground circuit.
3. Check the hydraulic circuit for leakage.
4. Speed sensor circuit
5. Deceleration sensor circuit
6. Yaw rate sensor circuit
7. Steering sensor circuit
8. If the symptoms still occur even after the above circuits
in suspected areas are inspected and proved to be
normal, replace the skid control ECU.05-765
05-827
-
05-788
05-795
05-815
05-824
05-824
05-821
SLIP indicator light abnormal1. SLIP indicator light circuit
2. Skid control ECU05-863
-

- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-787
977 Author
: Date
:
SymptomsSuspected AreasSee page
TRAC OFF indicator abnormal
1. Check the DTC again and make sure that the normal
code is output.
2. TRAC control switch circuit
3. If the symptoms still occur even after the above circuits
in suspected areas are inspected and proved to be
normal, replace the skid control ECU.05-765
05-859
DTC of VSC check cannot be done
1. Check the DTC again and make sure that the normal
code is output.
2. TC terminal circuit
3. If the symptoms still occur even after the above circuits
in suspected areas are inspected and proved to be
normal, replace the skid control ECU.05-765
05-868
VSC warning light abnormal Remain ON
1. Check the DTC again and make sure that the normal
code is output.
2. VSC warning circuit
3. If the symptoms still occur even after the above circuits
in suspected areas are inspected and proved to be
normal, replace the skid control ECU.05-765
05-847
VSC warning light abnormal Does not light up
1. Check the DTC again and make sure that the normal
code is output.
2. VSC warning circuit
3. If the symptoms still occur even after the above circuits
in suspected areas are inspected and proved to be
normal, replace the skid control ECU.05-765
05-851

051ZK-13
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-31
221 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
PROBLEM SYMPTOMS TABLE
SymptomSuspected AreaSee Page
Engine does not crank (does not start)
1. Starter
2. STARTER relay
3. PNP switch19-12
19-12
40-6
No initial combustion (does not start)
1. ECM power source circuit
2. Fuel pump control circuit
3. ECM05-312
05-349
01-36
No complete combustion (does not start)1. Fuel pump control circuit05-349
Difficult to start (engine cranks normally)
1. Starter signal circuit
2. Fuel pump control circuit
3. Compression05-235
05-349
14-1
Difficult to start with cold engine1. Starter signal circuit
2. Fuel pump control circuit05-235
05-349
Difficult to start with hot engine1. Starter signal circuit
2. Fuel pump control circuit05-235
05-349
High engine idle speed (poor idling)1. A/C signal circuit (Compressor circuit)
2. ECM power source circuit05-1 190
05-312
Low engine idle speed (poor idling)1. A/C signal circuit (Compressor circuit)
2. Fuel pump control circuit05-1 190
05-349
Rough idling (poor idling)1. Compression
2. Fuel pump control circuit14-1
05-349
Hunting (poor idling)1. ECM power source circuit
2. Fuel pump control circuit05-312
05-349
Hesitation/Poor acceleration (poor driveability)1. Fuel pump control circuit
2. A/T faulty05-349
05-904
Surging (poor driveability)1. Fuel pump control circuit05-349
Engine stalls soon after starting1. Fuel pump control circuit05-349
Engine stalls during A/C operation1. A/C signal circuit (Compressor circuit)
2. ECM05-1 190
01-36
Unable to refuel/Difficult to refuel1. ORVR system

7101E-06
- INSTRUMENT PANEL/METERCOMBINATION METER
71-1
3592 Author
: Date
:
COMBINATION METER
PROBLEM SYMPTOMS TABLE
Warning Lights:
SymptomSuspect AreaSee page
Check Engine warning light does not come on.
7. ECM
8. Wire Harness or Connector
9. Combination Meter Assy05-5
05-366
-
71-18
Discharge warning light does not come on.
1. ECM
2. Wire Harness or Connector
3. Combination Meter Assy05-5
05-366
-
71-18
Brake warning light does not come on.
1. Skid control ECU
2. Wire Harness or Connector
3. Combination Meter Assy05-761
-
71-18
ABS warning light does not come on.
1. ABS ECU
2. Wire Harness or Connector
3. Combination Meter Assy05-761
-
71-18
SRS warning light does not come on.
1. Airbag Sensor Assy Center
2. Wire Harness or Connector
3. Combination Meter Assy05-1200
-
71-18
Open Door warning light does not come on.
1. Refer to troubleshooting
2. Wire Harness or Connector
3. Combination Meter Assy05-1601
-
71-18
Fuel Level warning light does not come on.
1. Refer to troubleshooting
2. Wire Harness or Connector
3. Combination Meter Assy05-1893
-
71-18
Low Oil Pressure warning light does not come on.
1. Low Oil Pressure Warning Switch
2. Wire Harness or Connector
3. Combination Meter Assy71-3
-
71-18
Driver's seat belt warning light does not come on.
1. Refer to troubleshooting
2. Wire Harness or Connector
3. Combination Meter Assy05-1898
-
71-18
ºOIL LEVELº warning light does not come on.
1. Low Oil Level Sensor
2. Wire Harness or Connector
3. ECM
4. Combination Meter Assy05-5
05-366
-
05-5
05-366
71-18
ºTIRE AIR PRESSº warning light does not come on.
1. Wire Harness or Connector
2. Skid Control ECU
3. Combination Meter Assy-
05-761
71-18
Indicator Lights:
SymptomSuspect AreaSee page
Turn indicator light does not come on.
1. Turn Signal and Hazard Warning System
2. Wire Harness or Connector
3. Combination Meter Assy05-1533
-
71-18
High Beam indicator light does not come on.
1. Headlight Dimmer Switch
2. Wire Harness or Connector
3. Combination Meter Assy05-1533
-
71-18
Washer level indicator light does not come on.
1. Washer Level Warning Switch
2. Wire Harness or Connector
3. Combination Meter Assy-
-
71-18

71-2
- INSTRUMENT PANEL/METERCOMBINATION METER
3593 Author
: Date
:
MAINT REQD indicator ia blinking or cotinuously illuminated.1. Resetting procedure
2. Combination Meter Assy71-3
71-18
All buzzer (key reminder, tail cancel, Seat belt) does not operate.1. Refer to troubleshooting
2. Combination Meter Assy05-1879
71-18
O/D OFF indicator light does not come on.
1. O/D off Select Switch
2. Wire Harness or Connector
3. Combination Meter Assy-
-
71-18
SLIP indicator light does not come on.
1. Wire Harness or Connector
2. Skid Control ECU
3. Combination Meter Assy-
05-761
71-18
VSC indicator light does not come on.
1. Wire Harness or Connector
2. Skid Control ECU
3. Combination Meter Assy-
05-761
71-18
TRC/TRAC OFF indicator light does not come on.
1. Wire Harness or Connector
2. Skid Control ECU
3. Combination Meter Assy-
05-761
71-18
A/T OIL TEMP indicator light does not come on.
1. Wire Harness or Connector
2. Automatic transmission
3. Combination Meter Assy-
05-883
05-993
71-18
ECT SNOW indicator light does not come on.
1. Wire Harness or Connector
2. ECM
3. Combination Meter Assy-
05-5
05-366
71-18
A/T shift indicator light does not come on.
1. Park Neutral Position Switch
2. Wire Harness or Connector
3. ECM
4. Combination Meter Assy05-883
05-993
-
05-5
05-366
71-18
ºCRUISEº indicator light does not come on.
1. Wire Harness or Connector
2. ECM
3. Combination Meter Assy-
05-5
05-366
71-18
Meter Gauges:
SymptomSuspect AreaSee page
Speedometer does not operate.1. Refer to troubleshooting05-1885
Tachometer does not operate.1. Refer to troubleshooting05-1889
Fuel Gauge does not operate or operates abnormally.1. Refer to troubleshooting05-1893
Water temperature does not operate.1. Refer to troubleshooting05-1896
Clock:
SymptomSuspect AreaSee page
Clock will not operate
Clock loses or gains time
1. Power source or ground
2. Integration control & panel assy05-1 170
05-1 173
05-1 175
71-6

2701I-1 1
- REAR SUSPENSIONREAR SUSPENSION SYSTEM
27-1
2949 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
REAR SUSPENSION SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below, with suspected areas listed in numerical order, to determine the cause of the problem.
Inspect and repair or replace parts as necessary according to the steps on the following pages.
SymptomSuspected AreaSee page
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)-
27-7
27-7
Sways/pitches
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn)28-1
27-27
27-29
27-7
Rear wheel shimmy
1. Tire (Worn or improperly inflated)
2. Wheel (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Hub bearing (Worn)28-1
28-1
27-7
26-7
27-5
30-3
Abnormal tire wear
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn)
4. Suspension parts (Worn)28-1
26-7
27-5
27-7
-

BODY PANEL REPLACEMENT
F16772
220 mm (8.66 in.) 240 mm (9.45 in.)
F16772A
REMOVAL BP-36
QUARTER PANEL (CUT)
REPLACEMENT

BODY PANEL REPLACEMENT
F16773
BP-37