TOYOTA HIGHLANDER 2001 Service Repair Manual

Tool
Ta b
Ta b
Terminal
Retainer
Access Hole
( Mark)Tool
Tool
[Female] Example:
[Male] (Case 1)
[Male] [Female]Retainer
at Full Lock Position
Retainer
at Temporary Lock Position
Terminal Retainer
[Male]Press Down
[Female]Press DownTool
Tool Example:
(Case 2)
2005 HIGHLANDER (EWD592U)
15
C
[B] For Waterproof Type Connector
HINT : Ter m inal ret ainer color is diff er ent
according to connector body.
Example:
Terminal Retainer
: Connector Body
Black or White : Gray
Black or White : Dark Gray
Gray or White : Black
ºCase 1º
Type where terminal retainer is pulled
up to the temporary lock position (Pull
Type).
Insert the special tool into the terminal
retainer access hole (
Mark) and pull
the terminal retainer up to the
temporary lock position.
HINT : The needle insertion position varies
according to the connector 's shape
(Number of terminals etc.), so check
the position before inserting it.
ºCase 2º
Type which cannot be pulled as far as
Power Lock insert the tool straight into
the access hole of terminal retainer as
shown.

Retainer at
Full Lock Position
[Male] [Female] Retainer at
Temporary Lock Position
Locking Lug
Tool
2005 HIGHLANDER (EWD592U)
16
C TROUBLESHOOTING
Push the terminal retainer down to the temporary lock position.
(c)Release the locking lug from terminal and pull the terminal out
from rear.
4.INSTALL TERMINAL TO CONNECTOR
(a)Insert the terminal.
HINT:
1. Make sure the terminal is positioned correctly.
2. Insert the terminal until the locking lug locks firmly.
3. Insert the terminal with terminal retainer in the temporary lock
position.
(b)Push the secondary locking device or terminal retainer in to
the full lock position.
5.CONNECT CONNECTOR

F46320
Passenger Side J/B
D3 Data Link Connector 3
Skid Control ECU with Actuator
W-B
4L
4C
4N76
1
W-B12 424
S27
CG TS W-B
IC4TS
ICP-B 8
W
C52361
TS
CGDLC3
D3
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-873
1063 Author
: Date
:
TS AND CG TERMINAL CIRCUIT
CIRCUIT DESCRIPTION
In the sensor check mode, a malfunction of the speed sensor that cannot be detected when the vehicle is
stopped is detected while driving.
Transition to the sensor check mode can be performed by connecting terminals TS and CG of the DLC3 and
turning the ignition switch from off to the ON position.
WIRING DIAGRAM
INSPECTION PROCEDURE
1 INSPECT DLC3 TERMINAL VOLTAGE(TS TERMINAL)
(a) Turn the ignition switch to the ON position.
(b) Measure the voltage according to the value(s) in the table
below.
Standard:
Tester ConnectionSpecified Condition
D3-12 (TS) - D3-4 (CG)10 to 14 V
NG Go to step 3
OK
05F1Y-08

C52361G24767
I37493
Skid Control ECU
(harness side connector)
S27
TS
D3
DLC3TS
C52361CG
DLC3
D3
05-874
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
1064 Author
: Date
:
2 CHECK HARNESS AND CONNECTOR(DLC3 - BODY GROUND)
(a) Disconnect the skid control ECU connector.
(b) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSpecified Condition
S27-24 (TS) - D3-12 (TS)Below 1 W
(c) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSpecified Condition
S27-24 (TS) - Body ground10 kW or higher
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37)
3 CHECK HARNESS AND CONNECTOR(BODY GROUND - DLC3)
(a) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSpecified Condition
D3-4 (CG) - Body groundBelow 1 W
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK

C52361G24767
I37493
Skid Control ECU
(harness side connector)
S27
TS
D3
DLC3TS
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-875
1065 Author
: Date
:
4 CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - DLC3)
(a) Disconnect the skid control ECU connector.
(b) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSpecified Condition
S27-24 (TS) - D3-12 (TS)Below 1 W
(c) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSpecified Condition
S27-24 (TS) - Body ground10 kW or higher
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37)

Front
123
92 100 99
(3.62) (3.94) (3.90)
F-H G-iI-K
or or or
f-h g-Ii-k
294 1,251 999
(11.57) (49.25) (39.33)
Vehicle Dimensions(Three-Dimensional Distance)
Symbol Name Hole dia. Symbol Name Hole dia.mm (in.)
A, a
B, b
C, c
D, d
E, e
F, f
G, gFront bumper reinforcement installation nut
Front crossmember lower standard hole
Front side member standard hole
Front frame installation nut
Front side member standard hole
Front frame installation nut
Torque box front standard hole10 (0.39) nut
15 (0.59)
18 (0.71)
16 (0.63) nut
10 (0.39)
16 (0.63) nut
25 (0.98)H, h
I,i
J, j
K, k
L, l
M, m
N, nFront side member standard hole
Front floor under reinforcement standard hole
Rear strut bar installation hole inner
Rear floor side member standard hole
Rear suspension member installation nut
Rear suspension member installation nut
Transport hook installation nut25 (0.98)
18 (0.71)
12 (0.47)
18 (0.71)
14 (0.55) nut
10 (0.39) nut
10 (0.39) nut
Imaginary
Standard
Line
775
(30.51)
805
(31.69)
1,036
(40.79)
1,000
(39.37)
1,007
(39.65)
1,145
(45.08)
1,156
(45.51)
1,200
(47.24)
1,491
(58.70)1,023
(40.28)
1,218
(47.95)
1,100
(43.31)
883
(34.76)
658
(25.91)775
(30.51)
782
(30.79)
894
(35.20)
718
(28.27)
1,029
(40.51)696
(27.40)
1,346
(52.99)
1,088
(42.83)
1,070
(42.13)
1,170
(46.06)1,151
(45.31)
493
(19.41)548
(21.57)
646
(25.43)
1,091
(42.95)
1,182
(46.54)
548
(21.57)
1,265
(49.80)
1,011
(39.80)
1,187
(46.73)RH
LH
A,a
373
(14.69)B,b
165
(6.50)C,c
273
(10.75)D,d
163
(6.42)E,e
216
(8.50)F, f
87
(3.43)G,g
90
(3.54)1H,h
61
(2.40)2I,i
132
(5.20)3J,j
104
(4.09)K,k
142
(5.59)L,l
154
(6.06)M,m
271
(10.67)N,n
263
(10.35)
BODY DIMENSIONSDI-8
UNDER BODY
4WD

(Two-Dimensional Distance)
Symbol Name Hole dia. Symbol Name Hole dia.mm (in.)
A, a
B, b
C, c
D, d
E, e
F, f
G, g
H, h
I,iFront bumper reinforcement installation nut
Front crossmember lower standard hole
Front side member standard hole
Front frame installation nut
Front spring support hole outer-front
Front side member standard hole
Front frame installation nut
Torque box front standard hole
Front side member standard hole10 (0.39) nut
15 (0.59)
18 (0.71)
16 (0.63) nut
11 (0.43)
10 (0.39)
16 (0.63) nut
25 (0.98)
25 (0.98)K, k
M, m
N, n
O, o
P, p
Q, q
R, rFront floor under reinforcement standard hole
Rear strut bar installation hole inner
Rear floor side member standard hole
Rear suspension member installation nut
Rear spring support hole outer
Rear suspension member installation nut
Transport hook installation nut18 (0.71)
12 (0.47)
18 (0.71)
14 (0.55) nut
12.5 (0.492)
10 (0.39) nut
10 (0.39) nut
Imaginary
Standard
Line RH
123
92 100 99
(3.62) (3.94) (3.90)
Wheel base 2,720 (107.09)
Propeller shaft center support bearing
installation nut L, l 10 (0.39) nut
Propeller shaft center support bearing
installation nut J, j 10 (0.39) nut Ð Ð Ð
2,105
(82.87)
518
(20.39)1,890
(74.41)1,377
(54.21)1,000
(39.37)714
(28.11)881
(34.69)1,120
(44.09)1,598
(62.91)2,145
(84.45)
500
(19.69)
220
(8.66)
504
(19.84)
2,014
(79.29)1,782
(70.16)1,119
(44.06)870
(34.25)970
(38.19)1,427
(56.18)2,145
(84.45)
631
(24.84)
329
(12.95)
441
(17.36)
391
(15.39)
550
(21.65)
348
(13.70)
348
(13.70)
544
(21.42)
585
(23.03)
535
(21.06)506
(19.92)
665
(26.18)
549
(21.61)
543
(21.38)
108
(4.25)
70
(2.76)
111
(4.37)
68
(2.68) 303
(11.93)
303
(11.93)200
(7.87)200
(7.87)
Front
A,a
373
(14.69)B,b
165
(6.50)C,c
273
(10.75)D,d
163
(6.42)E,e
779
(30.67)F, f
216
(8.50)G,g
87
(3.43)H,h
90
(3.54)I,i
61
(2.40)J,j
120
(4.72)R,r
263
(10.35) Q,q
271
(10.67) P, p
757
(29.80) O,o
154
(6.06) N,n
142
(5.59) M,m
104
(4.09)
3 2
L,l
11 3
(4.45)10
0
LH
K,K
132
(5.20)
BODY DIMENSIONSDI-9
UNDER BODY
4WD

(Three-Dimensional Distance)
Symbol Name Hole dia. Symbol Name Hole dia.mm (in.)
A, a
B, b
C, c
D, d
E, e
F, f
G, gFront bumper reinforcement installation nut
Front crossmember lower standard hole
Front side member standard hole
Front frame installation nut
Front side member standard hole
Front frame installation nut
Torque box front standard hole10 (0.39) nut
15 (0.59)
18 (0.71)
16 (0.63) nut
10 (0.39)
16 (0.63) nut
25 (0.98)H, h
I,i
J, j
K, k
L, l
M, m
N, nFront side member standard hole
Front floor under reinforcement standard hole
Rear strut bar installation hole inner
Rear floor side member standard hole
Rear suspension member installation nut
Rear suspension member installation nut
Transport hook installation nut25 (0.98)
18 (0.71)
12 (0.47)
18 (0.71)
12 (0.47) nut
12 (0.47) nut
10 (0.39) nut
Imaginary
Standard
Line Front
123
92 100 99
(3.62) (3.94) (3.90)
F-H G-iI-K
or or or
f-h g-Ii-k
294 1,251 999
(11.57) (49.25) (39.33)
Vehicle Dimensions
775
(30.51)
805
(31.69)
1,036
(40.79)
1,000
(39.37)
1,007
(39.65)
1,145
(45.08)
1,156
(45.51)
1,200
(47.24)
1,491
(58.70)1,023
(40.28)1,100
(43.31)
883
(34.76)
658
(25.91)775
(30.51)
782
(30.79)
894
(35.20)
718
(28.27)
1,029
(40.51)696
(27.40)
1,346
(52.99)
1,130
(44.49)
1,170
(46.06)
1,005
(39.57)
1,036
(40.79)
317
(12.48)280
(11.02)608
(23.94)
989
(38.94)
1,206
(47.48)
1,091
(42.95)
1,201
(47.28)
607
(23.90)
1,218
(47.95)
RH
LH
A,a
373
(14.69)B,b
165
(6.50)C,c
273
(10.75)D,d
163
(6.42)E,e
216
(8.50)F, f
87
(3.43)G,g
90
(3.54)H,h
61
(2.40)1N,n
263
(10.35) M,m
261
(10.28) L,l
240
(9.45) K,k
142
(5.59)3 2I,i
132
(5.20)
1,088
(42.83)
J,j
104
(4.09)
BODY DIMENSIONSDI-7
UNDER BODY
2WD

(Two-Dimensional Distance)
Symbol Name Hole dia. Symbol Name Hole dia.mm (in.)
A, a
B, b
C, c
D, d
E, e
F, f
G, g
H, hFront bumper reinforcement installation nut
Front crossmember lower standard hole
Front side member standard hole
Front frame installation nut
Front spring support hole outer-front
Front side member standard hole
Front frame installation nut
Torque box front standard hole10 (0.39) nut
15 (0.59)
18 (0.71)
16 (0.63) nut
11 (0.43)
10 (0.39)
16 (0.63) nut
25 (0.98)I,i
J, j
K, k
L, l
M, m
N, n
O, o
P, pFront side member standard hole
Front floor under reinforcement standard hole
Rear strut bar installation hole inner
Rear floor side member standard hole
Rear suspension member installation nut
Rear spring support hole outer
Rear suspension member installation nut
Transport hook installation nut25 (0.98)
18 (0.71)
12 (0.47)
18 (0.71)
12 (0.47) nut
12.5 (0.492)
12 (0.47) nut
10 (0.39) nut
Imaginary
Standard
Line Front
123
92 100 99
(3.62) (3.94) (3.90)
Wheel base 2,720 (107.09)
2,105
(82.87)
518
(20.39)1,890
(74.41)1,377
(54.21)1,000
(39.37)714
(28.11)881
(34.69)1,260
(49.61)1,539
(60.59)2,145
(84.45)
500
(19.69)
220
(8.66)
504
(19.84)
2,014
(79.29)1,782
(70,16)1,119
(44.06)870
(34.25)970
(38.19)1,427
(56.18)2,145
(84.45)
631
(24.84)
329
(12.95)
441
(17.36)
391
(15.39)
550
(21.65)
348
(13.70)
348
(13.70)
544
(21.42)
585
(23.03)
503
(19.80)495
(19.49)
665
(26.18)
549
(21.61)
543
(21.38)
RH
LH
A,a
373
(14.69)B,b
165
(6.50)C,c
273
(10.75)D,d
163
(6.42)E,e
779
(30.67)F, f
216
(8.50)G,g
87
(3.43)H,h
90
(3.54)I,i
61
(2.40)J,j
132
(5.20)12K.k
104
(4.09)L,l
142
(5.59)M,m
240
(9.45)N,n
757
(29.80)O,o
261
(10.28)P, p
263
(10.35)3 0 0
BODY DIMENSIONSDI-8
UNDER BODY
2WD

VIEWS OF THIS TEXT
Scope of the repair work explanation

This text explains the welding panel replacement instructions from the vehicle's white body condi-
tion. We have abbreviated the explanations of the removal and reinstallation of the equipment parts
up to the white body condition and of the installation, inspection, adjustment and final inspection of
equipment parts after replacing the weld panel.
Section categories

Each section has been divided as shown below.
Section TitleContentsExamples
INTRODUCTIONExplanation of general body repair.
Views of weld panel replacement instructions.Cautionary items.
Views of weld panel replacement instructions.
BODY PANEL REPLACEMENT
Instructions for replacing the weld panels
from the white body condition, from which
bolted parts have been removed, with
individual supply parts.Front side member replacement.
Quarter panel replacement.
BODY DIMENSIONSBody aligning measurements.Dimension diagrams.
PAINT
COATINGScope and type of anti-rust treatment, etc.
together with weld panel replacement.Under coat.
Body sealer.
Abbreviation of contents in this text.

The following essential procedures have been abbreviated. When actually working, conduct this
work properly.
(1) Jack and lift operations.
(2) Clean and wash removed parts, if necessary.
(3) Visual inspection.