o2 sensor TOYOTA HIGHLANDER 2001 Service Repair Manual

- DIAGNOSTICSSFI SYSTEM (3MZ-FE)(From August, 2004)
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599 Author
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Hand-held Tester DisplayDiagnostic Note Normal Condition * Measurement Item/Range
(Display)
FUEL SYS #1
Fuel system status (Bank 1) /
OL or CL or OL DRIVE or
OL FAULT or CL FAULT
Idling after warming up: CL

OL (Open Loop): Has not yet sa-
tisfied conditions to go closed
loop

CL (Closed Loop): Using heated
oxygen sensor(s) as feed back
for fuel control

OL DRIVE: Open loop due to
driving conditions (fuel enrich-
ment)

OL FAULT: Open loop due to de-
tected system fault

CL FAULT: Closed loop but one
of heated oxygen sensors, which
is used for fuel control, is mal-
functioning
FUEL SYS #2
Fuel system status (Bank 2) /
OL or CL or OL DRIVE or
OL FAULT or CL FAULT
Idling after warming up: CL

OL (Open Loop): Has not yet sa-
tisfied conditions to go closed
loop

CL (Closed Loop): Using heated
oxygen sensor(s) as feed back
for fuel control

OL DRIVE: Open loop due to
driving conditions (fuel enrich-
ment)

OL FAULT: Open loop due to de-
tected system fault

CL FAULT: Closed loop but one
of heated oxygen sensors, which
is used for fuel control, is mal-
functioning
FC IDLFuel cut idle/ ON or OFFFuel cut operation: ON
FC IDL = ON when throttle valve
is fully closed and engine speed is
over 1,500 rpm
MILMIL status/ ON or OFFMIL ON: ON'
STARTER SIGStarter signal/ ON or OFFCranking: ON'
A/C SIGA/C signal/ ON or OFFA/C ON: ON'
PNP SW [NSW]PNP switch signal/ ON or OFFP or N position: ON'
ELECT LOAD SIGElectrical load signal/
ON or OFF
Taillamp switch ON: ON

Defogger switch ON: ON'
STOP LIGHT SWStop light switch/
ON or OFF
Brake pedal depressed: ON

Brake pedal released: OFF'
PS OIL PRESS SWPower steering oil pressure switch
signal/ ON or OFF

While turning the steering wheel:
ON

While not turning the steering
wheel: OFF
Idle-up control is performed when
PS is ON
PS SIGNALPower steering signal/
ON or OFFWhen steering wheel is turnedThis signal is usually ON until the
Ignition switch is turned OFF
INTAKE CTL VSV1VSV status for intake control (bank
1)/ ON or OFFVSV operation: ON'
INTAKE CTL VSV 2VSV status for intake control (bank
2)/ ON or OFFVSV operation: ON'
FUEL PUMP / SPDFuel pump/speed status/
ON/H or OFF/M, LIdling: ON'
A/C MAG CLUTCHA/C magnet clutch status/
ON or OFFA/C magnet clutch ON: ON'

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- DIAGNOSTICSSFI SYSTEM (3MZ-FE)(From August, 2004)
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Hand-held Tester DisplayDiagnostic Note Normal Condition * Measurement Item/Range
(Display)
EVAP VSVVSV status for EVAP control/
ON or OFFVSV operating: ONEVAP VSV is controlled by the
ECM (ground side duty control)
BOOST PRESS VSV
VSV status for boost pressure
control/
ON or OFF
VSV operating: ON'
IGNITIONIgnition counter/ Minimum: 0, Max-
imum: 6000 to 600'
CYL #1, #2, #3, #4, #5, #6Misfire ratio of cylinder 1 to 6/
Minimum: 0 %, Maximum: 50 %0 %This item is displayed in only idling
MISFIRE LOAD
Engine load for first misfire range/
Minimum: 0 g/rev, Maximum: 3.98
g/rev.
Misfire 0: 0 g/rev.'
MISFIRE RPM
Engine RPM for first misfire range/
Minimum: 0 rpm, Maximum: 6,375
rpm
Misfire 0: 0 rpm'
FC TAUFuel Cut TAU: Fuel cut during very
light load/ ON or OFFFuel cut operating: ON
Fuel cut is being performed under
very light load to prevent engine
combustion from becoming incom-
plete
CHECK MODECheck mode/ ON or OFFCheck mode ON: ONSee step 3
HINT:
*: If no conditions are specifically stated for ºldlingº, the shift lever is in the N or P position, the A/C switch
is OFF and all accessory switches are OFF.
2. ACTIVE TEST
HINT:
Performing the hand-held tester ACTIVE TEST allows relay, VSV, actuator and other items to be operated
without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to shorten
labor time. The DATA LIST can be displayed during the ACTIVE TEST.
(a) Warm up the engine.
(b) Turn the ignition switch OFF.
(c) Connect the hand-held tester or the OBD II scan tool to the DLC3.
(d) Turn the ignition switch ON.
(e) Turn ON the hand-held tester or the OBD II scan tool.
(f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST.
(g) According to the display on tester, perform the ºACTIVE TESTº.
Hand-held Tester DisplayTest DetailsDiagnostic Note
INJ VOL
[Test Details]
Control injection volume
Minimum: -12.5 %, Maximum: 25 %
[Vehicle Condition]
Engine speed: 3,000 rpm or less
All injectors are tested at once

Injection volume is gradually
changed between -12.5 and 25
%
A/F CONTROL
[Test Details]
Control injection volume
-12.5 or 25 % (change injection volume -12.5 % or 25 %)
[Vehicle Condition]
Engine speed: 3,000 rpm or less
Following A/F CONTROL proce-
dure enables technician to check
and graph voltage outputs of both
the A/F sensor and heated oxygen
sensor
For displaying graph, enter ºAC-
TIVE TEST / A/F CONTROL /
USER DATAº, select ºAFS B1S1
and O2S B1S2º by pressing ºYESº
and push ºENTERº. Then press
ºF4º

0.02 inch orifice clogged
Pressure sensor low outputP043E
P043FP0441 P0451 P0452 P0453 P0455 P0456 P2419P2401
P2402
0.02 inch orifice high-flow
Pressure sensor stuck
Pressure sensor noise
Gross leak
Small leak
Vacuum pump stuck OFF
Vacuum pump stuck ON
Vent valve stuck closed
Vent valve stuck open (vent) Purge VSV stuck open
Purge VSV stuck closed
Pressure sensor high output
DTCs
Malfunctioning AreasP2420 P0450
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
EVAP INSPECTION PROCEDURE
DTCS RELATING TO EVAP SYSTEM
DTCsMonitoring ItemsSee Page
P043E0.02 inch orifice clogged (built into pump module)05-190
P043F0.02 inch orifice high-flow (built into pump module)05-190
P0441

Purge VSV (Vacuum Switching Valve) stuck closed

Purge VSV stuck open

Purge flow
05-196
P0450Pressure sensor (built into pump module) voltage abnormal fluctuation05-202
P0451
Pressure sensor (built into pump module) noising

Pressure sensor stuck (built into pump module)05-202
P0452Pressure sensor (built into pump module) voltage low05-202
P0453Pressure sensor (built into pump module) voltage high05-202
P0455EVAP gross leak05-21 1
P0456EVAP small leak05-21 1
P2401Vacuum pump stuck OFF (built into pump module)05-288
P2402Vacuum pump stuck ON (built into pump module)05-288
P2419Vent valve stuck closed (built into pump module)05-294
P2420Vent valve stuck open (vent) (built into pump module)05-294
P2610Soak timer (built into ECM)05-300
If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below.
NOTICE:
If the 0.02 inch reference pressure difference between the first and second checks is greater than
the specification, the DTCs corresponding to the reference pressure (P043E, P043F, P0441, P0455,
P0456, P2401, P2420) will be all stored.
05IRG-02

A93865Purge VSV
EVAP Hose
(To Throttle Body)
EVAP Hose
(From Canister)
Vent ValveCanister
Air Filter
Pump ModulePressure Sensor
Vacuum Pump
Purge Line
Refueling Valve
Fuel Tank
Fuel Cap
Location of EVAP (Evaporative Emission) system:
A93866
EVAP System Circuit
Intake Manifold
Purge VSV
Cut-of f Valve Roll-over Valve
CanisterAir FilterFuel Cap
Service Port
Air Cleaner
Restrictor (0.08 inch)
Refueling Valve Throttle Valve
ECM
Soak Timer
Pump Module (refer to fig. 1)
Fuel Tank 05-318
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
CIRCUIT DESCRIPTION
While the engine is running, if a predetermined condition (closed-loop, etc.) is met, the purge VSV is opened
by the ECM and stored fuel vapors in the canister are purged to the intake manifold. The ECM changes the
duty cycle ratio of the purge VSV to control purge flow volume.
The purge flow volume is also determined by the intake manifold pressure.
Atmospheric pressure is allowed
into the canister through the vent valve to ensure that the purge flow is maintained when the negative pres-
sure (vacuum) is applied to the canister.
The following two monitors run to confirm appropriate EVAP system operation.

A97610
EVAP Purge Flow:
Canister Purge VSV
(ON)
Vacuum Pump (OFF)Air Filter Fuel Tank fuel tank cap
To Intake Manifold
Pump Module
Pressure Sensor0.02 Inch Orifice
Vent Valve (OFF)
ECM
Soak Timer
Refueling Valve
To Atmosphere
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
Key-off monitor
This monitor checks for EVAP (Evaporative Emission) system leaks and pump module malfunctions. The
monitor starts 5 hours*
after the ignition switch is turned OFF. More than 5 hours are required to allow enough
time for the fuel to cool down to stabilize the Fuel Tank Pressure (FTP), thus making the EVAP system moni-
tor more accurate.
The electric vacuum pump creates negative pressure (vacuum) in the EVAP system and the pressure is
measured. Finally, the ECM monitors for leaks from the EVAP system, and malfunctions in both the pump
module and purge VSV, based on the EVAP pressure.
HINT:
*:If the engine coolant temperature is not below 35C 5 hours after the ignition switch is turned off, the moni-
tor check starts 2 hours later. If it is still not below 35C 7 hours after the ignition switch is turned off, the
monitor check starts 2.5 hours later.
Purge flow monitor
The purge flow monitor consists of the two monitors. The 1st monitor is always conducted every time and
the 2nd monitor is activated if necessary.

The 1st monitor
While the engine is running and the purge VSV (Vacuum Switching Valve) is ON (open), the ECM
monitors the purge flow by measuring the EVAP pressure change. If negative pressure is not
created, the ECM begins the 2nd monitor.

The 2nd monitor
The vent valve is turned ON (closed) and the EVAP pressure is then measured. If the variation
in the pressure is less than 0.5 kpa (3.75 mmHg), the ECM interprets this as the purge VSV being
stuck closed, and illuminates the MIL and sets DTC P0441 (2 trip detection logic).
Atmospheric pressure check:
In order to ensure reliable malfunction detection, the variation between the atmospheric pressures, before
and after conduction of the purge flow monitor, is measured by the ECM.

05-320
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)Components
Operations
CanisterContains activated charcoal to absorb EVAP (Evaporative Emissions) generated in fuel tank.
Cut-of f valveLocated in fuel tank. Valve floats and closes when fuel tank is 100 % full.
Purge VSV (Vacuum
Switching Valve)Opens or closes line between canister and intake manifold. ECM uses purge VSV to control EVAP purge flow. In order
to discharge EVAP absorbed by canister to intake manifold, ECM opens purge VSV. EVAP discharge volume to intake
manifold controlled by purge VSV duty cycle ratio (current-carrying time). (Open: ON, Close: OFF)
Refueling valve
Controls EVAP pressure from fuel tank to canister. Valve consists of diaphragm, spring and restrictor (diameter: 0.08
inch). When fuel vapor and pressure inside fuel tank increase, valve opens. While EVAP purged, valve closes and re-
strictor prevents large amount of vacuum from affecting pressure in fuel tank. Valve opened while refueling. When valve
open, adding fuel into fuel tank possible.
Roll-over valveLocated in fuel tank. Valve closes by its own weight when vehicle overturns to prevent fuel from spilling out.
Service portUsed for connecting vacuum gauge for inspecting EVAP system.
Soak timerBuilt into ECM. To ensure accurate EVAP monitor, measures 5 hours* after ignition switch turned to OFF. This allows
fuel to cool down, stabilizing Fuel Tank Pressure (FTP). When apprx. 5 hours
* elapsed, ECM activates.
Pump moduleConsists of (a) to (d) below. Pump module cannot be disassembled.
(a) Vent valve
Vents and closes EVAP system. When ECM turns valve ON, EVAP system closed. When, ECM turns valve OFF, EVAP
system vented. Negative pressure (vacuum) created in EVAP system to check for EVAP leaks by closing purge VSV,
turning on vent valve (closed) and operating vacuum pump (refer to fig. 1).
(b) Pressure sensorIndicates pressure as voltages. ECM supplies regulated 5 V to pressure sensor, and uses feedback from sensor to
monitor EVAP system pressure (refer to fig 2).
(c) Vacuum pumpCreates negative pressure (vacuum) in EVAP system for leak check.
(d) 0.02 inch orificeHas opening with 0.02 inch diameter. Vacuum produced through orifice by closing purge VSV, turning off vent valve and
operating vacuum pump, to monitor 0.02 inch leak pressure. 0.02 inch leak pressure indicates small leak of EVAP.
HINT:
*:If the engine coolant temperature is not below 35C after 5 hours after the ignition switch is turned off, the
monitor check starts 2 hours later. If it is still not below 35C 7 hours after the ignition switch is turned off,
the monitor check starts 2.5 hours later.

A97611
Pump Module (fig. 1)
Condition: Purge FlowCondition: Leak Check
From Refueling Valve
To Air Filter
(Atmosphere)
Vacuum Pump: OFFVent Valve: OFF
(vent)
Pressure Sensor 0.02 Inch Orifice
Canister
: Airflow
Vacuum Pump: ON
Vent Valve: ON
(closed)
A71562
Pressure Sensor Specification (fig. 2)
Output Voltage
Usable Range
4.900 V
4.150 V
1.425 V
0.450 V
Malfunction Area
Pressure
60
kPa11 0
kPa
Malfunction Area
Standard atmospheric pressure is 101.3 kPaHINT:
A85251
Soak Timer Circuit (fig. 3)
Ignition Switch
IGSW
Power
ECM
EFI MAIN
MREL+B
15 ASource IC
Soak Timer IC Main Relay
Control IC
Battery
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)

A85256
C17
Pump Module
BJ1 IO1 IM1E7
E5
E7
E5
E5
E7
E5 18
21
28
4
27
34
8VC
PPMP
E2
MPMP
VPMP
PRG
MRELECM
5V
Pressure Sensor
BJ1 IO1 IM1
BJ1 IO1 IM1
BJ1 IO1 IM1 BJ1 IO1 BJ1 IO1
EB1 16 7 13
12 3
17 15 12
14 5 14
18 16 513 4
1S28
S295 5
LG
BJ1 15
J19
J/C
BFBatteryEH
J2
J/C A AFL MAIN
W
W-B W-B
W-B
2
2I1
2F4EFI No. 2
EFI No. 1EFI Relay
2 53
113
IK3 P-L B
2B2D3
52
Y Engine Room J/BB-R
B-R
Vacuum Pump
Vent Valve
4
3
2
1
8
9Y
YY LLP
L
BRBRBR
WW
BR
RVSB
GRY-G BRBR
B-R
G 12
V4
Purge VSV 6 05-322
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
WIRING DIAGRAM

0.02 inch orifice clogged
Pressure sensor low outputP043E
P043FP0441 P0451 P0452 P0453 P0455 P0456 P2419P2401
P2402
0.02 inch orifice high-flow
Pressure sensor stuck
Pressure sensor noise
Gross leak
Small leak
Vacuum pump stuck OFF
Vacuum pump stuck ON
Vent valve stuck closed
Vent valve stuck open (vent) Purge VSV stuck open
Purge VSV stuck closed
Pressure sensor high output
DTCs
Malfunctioning AreasP2420 P0450
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
INSPECTION PROCEDURE
NOTICE:
A hand-held tester is required to conduct the following diagnostic troubleshooting procedure.
HINT:

Using hand-held tester monitor results enables the EVAP (Evaporative Emission) system to be con-
firmed.

Read freeze frame data using a hand-held tester Freeze frame data record the engine condition when
malfunctions are detected. When troubleshooting, freeze frame data can help determine if the vehicle
was moving or stationary, if the engine was warmed up or not, if the air-fuel ratio was lean or rich, and
other data, from the time the malfunction occurred.
1 CONFIRM DTC
(a) Turn the ignition switch OFF and wait 10 seconds.
(b) Turn the ignition switch ON.
(c) Turn the ignition switch OFF and wait 10 seconds.
(d) Connect the hand-held tester to the DLC3.
(e) Turn the ignition switch ON and press the hand-held tester switch ON.
(f) Enter the following menus: DIAGNOSIS/ ENHANCED OBD II/ DTC INFO/ CURRENT CODES.
(g) Confirm the DTCs and freeze frame data.
If any EVAP system DTCs are set, the malfunctioning area can be determined using the table below.
NOTICE:
If the 0.02 inch reference pressure difference between the first and second checks is greater than
the specification, the DTCs corresponding to the reference pressure (P043E, P043F, P0441, P0455,
P0456, P2401, P2420) will be all stored.
NEXT

G36783
Purge VSV
Vent Valve
Vacuum Pump
EVAP Pressure
Positive
ON: Open
NegativeONON
Steps
(Reference)
ON
OFF: Closed
OFF: Vent ON: Closed
10
sec
1/5
Time
Pressure Sensor Noising
OK
Leak Pressure First 0.02 inch
Standard
05-326
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
4 PERFORM EVAP SYSTEM CHECK(STEP 1/5)
(a) Check the EVAP pressure in step 1/5.
Result:
DTCs*Test ResultsSuspected Trouble AreasProceed To
'Virtually no variation in EVAP pressureNot yet determinedA
P0451EVAP pressure fluctuates by
0.3 kPa
(2.25 mmHg) or morePressure sensor noisingB
*: The DTCs relating to the EVAP system displayed on a hand-held tester when checking.
B Go to step 30
A