air filter TOYOTA HIGHLANDER 2001 Service Manual PDF

A96746
Fuel Tank Canister
Vacuum Pump: OFF Pressure Sensor 0.02 Inch Orifice
Pump Module
Operation A: Atmospheric Pressure Measurement
Vent Valve: OFF (vent)
Operation D: Purge VSV monitor Operation B, E: 0.02 Inch Leak Pressure Measurement
Negative
Pressure Atmospheric
Pressure Air Filter
Purge VSV: OFFOFF (vent)
ON
OFF
OFF
ON
ON (closed)ON
ON
ON (closed)
Operation C: EVAP System Pressure Measurement
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)(From August, 2004)
05-295
485 Author
: Date
:
MONITOR DESCRIPTION
5 hours* after the ignition switch is turned OFF, the electric vacuum pump creates negative pressure (vacu-
um) in the EVAP (Evaporative Emission) system. The ECM monitors for leaks and actuator malfunctions
based on the EVAP pressure.
HINT:
*: If the engine coolant temperature is not below 35C (95F) 5 hours after the ignition switch is turned off,
the monitor check starts 2 hours later. If it is still not below 35C (95F) 7 hours after the ignition switch is
turned off, the monitor check starts 2.5 hours later.
SequenceOperationsDescriptionsDuration
-ECM activationActivated by soak timer, 5 hours (7 or 9.5 hours) after ignition switch turned to OFF.-
AAtmospheric pressure
measurement
Vent valve turned OFF (vent) and EVAP system pressure measured by ECM in order to
register atmospheric pressure.
If EVAP pressure is not between 70 kPa and 110 kPa (525 mmHg and 825 mmHg), ECM
cancels EVAP system monitor.
10 seconds
B
First 0.02 inch leak
pressure measure-
mentIn order to determine 0.02 inch leak pressure standard, vacuum pump creates negative pres-
sure (vacuum) through 0.02 inch orifice and them ECM checks if vacuum pump and vent
valve operate normally.
60 seconds
CEVAP system pres-
sure measurement
Vent valve turned ON (closed) to shut EVAP system.
Negative pressure (vacuum) created in EVAP system, and EVAP system pressure then
measured.
Write down the measured value as it will be used in the leak check.
If EVAP pressure does not stabilize within 15 minutes, ECM cancels EVAP system monitor.
15 minutes*
DPurge VSV monitorPurge VSV opened and then EVAP system pressure measured by ECM.
Large increase indicates normal.10 seconds
E
Second 0.02 inch leak
pressure measure-
mentLeak check is performed after second 0.02 inch leak pressure standard is measured.
If stabilized system pressure higher than second 0.02 inch leak pressure standard, ECM
determines that EVAP system leaking.
60 seconds
FFinal checkAtmospheric pressure measured and then monitoring result recorded by ECM.-
* If only a small amount of fuel is in the fuel tank, it takes longer for the EVAP pressure to stabilize.

100IU-03
A93427N´m (kgf´cm, ft´lbf) : Specified torque
7.9 (81, 70 in.Vlbf)x 3
V-Bank Cover Sub-assy
Vacuum Hose
Air Cleaner Filter Element
Sub-assy Air Cleaner Cap Sub-assyMAF Meter
Connector Fuel Vapor Feed Hose Assy
Vacuum Hose
w/ Performance Rod:
Front Suspension Upper Brace Center
Spacer
80 (815, 59)
Spacer
x 2
x 2
80 (815, 59)
10-16
- ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (3MZ-FE)
2374 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
THROTTLE BODY ASSY (3MZ-FE)
COMPONENTS

141P0-02
A87787
CORRECTINCORRECT
A80020
Hand-held Tester
DLC3
A82779
7 6 5 34 2 18
9 10111213141516DLC3
CG
TC
- ENGINE MECHANICALENGINE (2AZ-FE)
14-1
2494 Author
: Date
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
ENGINE (2AZ-FE)
INSPECTION
1. INSPECT ENGINE COOLANT (See page 16-6)
2. INSPECT ENGINE OIL
3. INSPECT BATTERY
4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSY
5. INSPECT SPARK PLUG (See page 18-3)
6. INSPECT V-RIBBED BELT
HINT:

After installing the drive belt, check that it fits properly in
the ribbed grooves. Check with your hand to confirm that
the belt has not slipped out of the groove on the bottom
of the crank pulley.

ºNew beltº is a belt which has been used less than 5 min-
utes on a running engine.

ºUsed beltº is a belt which has been used on a running en-
gine for 5 minutes or more.

After installing a new belt, run the engine for approximate-
ly 5 minutes and then recheck the tension.
7. INSPECT IGNITION TIMING
(a) Warm up the engine.
(b) When using the hand-held tester:
Check the ignition timing.
(1) Connect the hand-held tester to the DLC3.
(2) Enter DATA LIST MODE on the hand-held tester.
Ignition timing: 8 to 12 BTDC @ idle
HINT:
Please refer to the hand-held tester operator's manual for help
on selecting the DATA LIST.
(c) When not using the hand-held tester:
Check the ignition timing.
(1) Using SST, connect terminals 13 (TC) and 4 (CG)
of the DLC3.
SST 09843-18040
NOTICE:

Confirm the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn off all electrical systems before connecting the
terminals.

Perform this inspection after the cooling fan motor is
turned off.

14-4
- ENGINE MECHANICALENGINE (2AZ-FE)
2497 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)CO
HCProblemsCauses
NormalHighRough idle
1. Faulty ignitions:

Incorrect timing

Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaky intake and exhaust valves
4. Leaky cylinders
LowHighRough idle
(fluctuating HC reading)
1. Vacuum leaks:

PCV hoses

Intake manifold

Throttle body

Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(black smoke from exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI system:

Faulty pressure regulator

Defective ECT

Defective MAF meter

Faulty ECM

Faulty injectors

Faulty throttle position sensor

D25080
Negative (-)
Terminal
D31751
INCORRECT
- INTRODUCTIONREPAIR INSTRUCTION
01-15
15 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(i) WIRE HARNESS AND CONNECTOR
(1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All the con-
nectors in the system are a standard yellow color. If the SRS wire harness becomes discon-
nected or the connector becomes broken, repair or replace it.
2. ELECTRONIC CONTROL
(a) REMOVAL AND INSTALLATION OF BATTERY TERMI-
NAL
(1) Before performing electronic work, disconnect the
battery negative (-) terminal cable beforehand to
prevent component and wire damage caused by
accidental short circuits.
(2) When disconnecting and installing the terminal
cable, turn the ignition switch and lighting switch
OFF and loosen the terminal nut completely. Per-
form these operations without twisting or prying the
terminal. Remove the battery cable from battery
post.
(3) Clock settings, radio settings, DTCs and other data
are erased when the battery cable is removed. Be-
fore removing the battery cable, record any neces-
sary data.
(4) When disconnecting the battery's negative (-) ter-
minal cable, re-initialize the following systems after
the completion of the operation.
(b) HANDLING OF ELECTRONIC PARTS
(1) Do not open the cover or case of the ECU unless
absolutely necessary. If the IC terminals are
touched, the IC may be rendered inoperative by
static electricity.
(2) To disconnect electronic connectors, pull the con-
nector itself, not the wires.
(3) Be careful not to drop electronic components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced.
(4) When cleaning the engine with steam, protect the
electronic components, air filter and emission-re-
lated components from water.
(5) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(6) When checking the continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.

- 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

L
CodePart Name Part NumberCodePart Name Part Number
2005 HIGHLANDER (EWD592U)
343
E 4Electronically Controlled Transmission
Pattern Select SW90980-10797
E 5Engine Control Module90980-12142
E 6Engine Control Module90980-12146
E 7Engine Control Module90980-12144
E 8Engine Control Module90980-12145
E 9Engine Control Module90980-12143
E10Electronically Controlled Transmission
Solenoid90980-1 1658
E12Evaporator Temp. Sensor90980-1 1918
F 1Front Fog Light LH90980-1 1660F 2Front Fog Light RH90980-1 1660
F3Front Parking Light LHF 3Front Turn Signal Light LH90980-1 1020
F4Front Parking Light RH90980-1 1020
F 4Front Turn Signal Light RH
F 5Front Wiper Deicer90980-1 1407
F 6Front Wiper Motor90980-1 1599
F 7Fusible Link Block-
F 8Front Power Outlet90980-10760
F10Front Door Speaker LH90980-10935F11Front Door Speaker RH90980-10935
F12Fuel Pump90980-1 1077F12Fuel Sender90980-11077
F14Front Washer Motor90980-1 1019
G 1Generator90980-1 1964
G 2Generator90980-09365
G 4Glove Box Light90980-1 1098
G 5Gateway ECU90980-1 1911
H 1Headlight LH (High Beam)90980-1 1659
H 2Headlight LH (Low Beam)90980-1 1660
H 3Headlight RH (High Beam)90980-1 1659
H 4Headlight RH (Low Beam)90980-1 1660
H 6Heated Oxygen Sensor (Bank 2 Sensor 2)90980-1 1930
H 7Horn LH90980-10619H 8Horn RH90980-10619
H 9Heater Relay82660-44010
H10Heated Oxygen Sensor (Bank 1 Sensor 2)90980-1 1929
H11High Mounted Stop Light90980-1 1148
I 2Ignition Coil and Igniter No.1
I 3Ignition Coil and Igniter No.2
I 4Ignition Coil and Igniter No.390980-1 1885I 5Ignition Coil and Igniter No.490980-1 1885
I 6Ignition Coil and Igniter No.5
I 7Ignition Coil and Igniter No.6
I8Injector No.1 (2AZ-FE)90980-1 1875I 8Injector No.1 (3MZ-FE)90980-1 1153
I9Injector No.2 (2AZ-FE)90980-1 1875I 9Injector No.2 (3MZ-FE)90980-1 1153
I10Injector No.3 (2AZ-FE)90980-1 1875I10Injector No.3 (3MZ-FE)90980-1 1153
I11Injector No.4 (2AZ-FE)90980-1 1875I11Injector No.4 (3MZ-FE)90980-1 1153
I12Injector No.590980-1 1153I13Injector No.690980-11153
I14Ignition Key Cylinder Illumination90980-1 1148
I15Ignition SW90980-1 1615
I16Interior Light90980-10908
I17Inner Mirror90980-1 1794
J 1Junction Connector
J 2Junction Connector90980-1 1194J 3Junction Connector90980-1 1194
J 4Junction Connector
J 5Junction Connector90980-1 1542
J 6Junction Connector90980-1 1915
J 7Junction Connector90980-1 1542
J10Junction Connector90980-10807J12Junction Connector90980-10807
J13Junction Connector90980-1 1915
J14Junction Connector90980-10976
J16Junction Connector90980-1 1915J17Junction Connector90980-1 1915
J18Junction Connector
J19Junction Connector90980-1 1542
J20Junction Connector
J21Junction Connector
J22Junction Connector90980-12374J23Junction Connector90980-12374
J24Junction Connector
K 1Knock Sensor (Bank 1)
K 2Knock Sensor (Bank 1)90980-1 1875
K 3Knock Sensor (Bank 2)
K4Key Interlock Solenoid90980-10795K 4Unlock Warning SW90980-10795
L 1License Plate light90980-1 1300
M 1Mass Air Flow Meter90980-1 1317
M 2Main SW90980-10957
M 3Multi-Display90980-12203
M 4Multi-Display90980-12410
M 5Multi-Display90980-12012
N 1Noise Filter (Ignition System)90980-10843
N 2Noise Filter (Rear Window Defogger)90980-10860
N 3Navigation ECU90980-1 1973

2005 HIGHLANDER (EWD592U)
39
G
Position of Parts in Engine Compartment
[3MZ-FE]
I 2 Ignition Coil and Igniter No.1
I 3 Ignition Coil and Igniter No.2
I 4 Ignition Coil and Igniter No.3
I 5 Ignition Coil and Igniter No.4
I 6 Ignition Coil and Igniter No.5
I 7 Ignition Coil and Igniter No.6
I 8 Injector No.1
I 9 Injector No.2
I 10 Injector No.3
I 11 Injector No.4
I 12 Injector No.5
I 13 Injector No.6
J 1 Junction Connector
J 2 Junction Connector
J 3 Junction Connector
J 4 Junction Connector
K 2 Knock Sensor (Bank 1)
K 3 Knock Sensor (Bank 2)
M 1 Mass Air Flow Meter
N 1 Noise Filter (Ignition System)
O 1 Oil Pressure SWP 1 A/T Indicator SW
Back-Up Light SW
Park/Neutral Position SW
P 2 Power Steering Oil Pressure SW
R 1 Radiator Fan Motor
R 21 Rear Washer Motor
S 1 Starter
S 2 Starter
S 27 Skid Control ECU with Actuator
T 1 Theft Deterrent Horn
T 3 Turbine Speed Sensor
T 13 Throttle Control Motor
Throttle Position Sensor
V 2 VSV (ACIS No.2)
V 4 VSV (EVAP)
V 5 VSV (ACM)
V 6 VVT Sensor LH
V 7 VVT Sensor RH
W 1 Washer Level Sensor
W 3 Water Temp. SW No.1
W 4 Water Temp. SW No.2
W 5 Wireless Door Lock Buzzer

2005 HIGHLANDER (EWD592U)
41
G
Position of Parts in Engine Compartment
[2AZ-FE]
I 2 Ignition Coil and Igniter No.1
I 3 Ignition Coil and Igniter No.2
I 4 Ignition Coil and Igniter No.3
I 5 Ignition Coil and Igniter No.4
I 8 Injector No.1
I 9 Injector No.2
I 10 Injector No.3
I 11 Injector No.4
J 1 Junction Connector
J 2 Junction Connector
J 3 Junction Connector
J 4 Junction Connector
K 1 Knock Sensor (Bank 1)
M 1 Mass Air Flow Meter
N 1 Noise Filter (Ignition System)
O 1 Oil Pressure SWP 1 A/T Indicator SW
Back-Up Light SW
Park/Neutral Position SW
P 2 Power Steering Oil Pressure SW
R 1 Radiator Fan Motor
R 21 Rear Washer Motor
S 1 Starter
S 2 Starter
S 27 Skid Control ECU with Actuator
T 3 Turbine Speed Sensor
T 13 Throttle Control Motor
Throttle Position Sensor
V 4 VSV (EVAP)
W 1 Washer Level Sensor
W 5 Wireless Door Lock Buzzer

2005 HIGHLANDER (EWD592U)
44
G ELECTRICAL WIRING ROUTING
Position of Parts in Body
A 24 ABS Speed Sensor Rear LH
A 25 ABS Speed Sensor Rear RH
A 26 Antenna Amplifier (Rear)
B 14 Back Door Key Lock and Unlock SW
B 15 Back Door Lock Motor
Back Door Unlock Detection SW
C 17 Charcoal Canister Assembly
C 18 Curtain Shield Airbag Squib LH
C 19 Curtain Shield Airbag Squib RH
D 4 Diode (Rear Interior Light)
D 5 Door Courtesy Light Front LH
D 6 Door Courtesy Light Front RH
D 7 Door Courtesy SW Front LH
D 8 Door Courtesy SW Front RH
D 9 Door Courtesy SW Rear LH
D 10 Door Courtesy SW Rear RH
D 11 Door Lock Control SW
D 12 Door Key Lock and Unlock SW Front LH
Door Lock Motor Front LH
Door Unlock Detection SW Front LH
D 13 Door Key Lock and Unlock SW Front RH
Door Lock Motor Front RH
Door Unlock Detection SW Front RH
D 14 Door Lock Motor Rear LH
Door Unlock Detection SW Rear LH
D 15 Door Lock Motor Rear RH
Door Unlock Detection SW Rear RHF 10 Front Door Speaker LH
F 11 Front Door Speaker RH
F 12 Fuel Pump
Fuel Sender
H 11 High Mounted Stop Light
I 16 Interior Light
I 17 Inner Mirror
J 10 Junction Connector
J 12 Junction Connector
J 13 Junction Connector
J 14 Junction Connector
J 18 Junction Connector
J 19 Junction Connector
L 1 License Plate light
N 2 Noise Filter (Rear Window Defogger)
O 5 Overhead J/B
P 5 Power Window Master SW with ECU
P 6 Power Window Motor Front LH
P 7 Power Window Motor Front RH
P 8 Power Window Motor Rear LH
P 9 Power Window Motor Rear RH
P 10 Power Window SW Front RH
P 11 Power Window SW Rear LH
P 12 Power Window SW Rear RH
P 13 Pretensioner LH
P 14 Pretensioner RH
P 23 Power Outlet (110V)