o2 sensor TOYOTA HIGHLANDER 2001 Service Repair Manual

SFI
SFISFI
SFISFI
SFISFI
SFI
D25842

Circuit Description
The major role, operation of the circuit and its
component parts are explained.

Diagnostic Trouble Code No. and Detection Item

Indicates the diagnostic trouble codes, diagnostic
trouble code settings and suspect areas for a
problem.
Wiring Diagram
This shows a wiring diagram of the circuit.
Use this diagram together with ELECTRICAL
WIRING DIAGRAM to thoroughly understand the
circuit.
Wire colors are indicated by an alphabetical code.
B = Black, L = Blue, R = Red, BR = Brown,
LG = Light Green, V = Violet, G = Green,
O = Orange, W = White, GR = Gray, P = Pink,
Y = Yellow, SB = Sky Blue
The first letter indicates the basic wire color and
the second letter indicates the color of the stripe.
Inspection Procedures
Use the inspection procedures to determine
if the circuit is normal or abnormal. If it is ab-
normal, use it to determine whether the prob-
lem is located in the sensors, actuators, wire
harness or ECU.

Indicates the condition of the connector of the ECU
during the check.


Connections of tester are
indicated by (+), (-) after
terminals name.
Connector being checked
is connected.Connector being checked
is disconnected.
For inspection of connector
with body ground, there is
nothing about the body
ground written down.
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01-35
35 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
CIRCUIT INSPECTION
How to read and use each page is shown below.

I44266
ECM
E2
THW E719 E728
BR
G-BBR*1
1
2 5
S29 S285
E2
Engine
Coolant
Temp Sensor Short ConnectorC11
Combination Meter Assy
BEANMPX- 21
*1: 2AZ-FE
*2: 3MZ-FEW-B*2 BR
05-1896
- DIAGNOSTICSCOMBINATION METER
2086 Author
: Date
:
MALFUNCTION IN WATER TEMPERATURE RECEIVER GAUGE
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
If there is an open or short in the engine coolant temperature sensor circuit, the ECM outputs DTCs. Perform
troubleshooting with the ºSFI System 05-5,.05-366º.
1 PERFORM ACTIVE TEST BY HAND-HELD TESTER
(a) Operate the hand-held tester according to the steps on the display and select the ºACTIVE TESTº.
METER:
ItemTest DetailsDiagnostic Note
COOLANT TEMPLOW / NORMAL / HI-
OK:
Needle indication is normal.
NG REPLACE COMBINATION METER ASSY
(SEE PAGE 71-18)
OK
05IQ0-05

- DIAGNOSTICSCOMBINATION METER
05-1897
2087 Author
: Date
:
2 READ VALUE OF HAND-HELD TESTER(ENGINE COOLANT)
(a) Operate the hand-held tester according to the steps on the display and select the ºDATA LISTº.
ECM:
ItemMeasurement Item/
Range (Display)Normal ConditionDiagnostic Note
COOLANT TEMPCoolant Temperature / Min.: -40
C
(-40°F), Max.: 140
C (284°F)After warming up: 80 to 95°C (176
to 203°F)If the value is º-40
C (-40°F)º or
º140
C (284°F)º, sensor circuit is
open or shorted.
OK:
Coolant temperature displayed on the tester is between 80
C (176
F) and 95
C (203
F) after
warning up.
NG GO TO ENGINE CONTROL SYSTEM
(SEE PAGE 05-5, 05-366)
OK
3 REPLACE COMBINATION METER ASSY
OK:
Normal operation
NG GO TO ENGINE CONTROL SYSTEM
(SEE PAGE 05-5, 05-366)
OK
END

18091-05
CHECK POWER SUPPLY TO IGNITION COIL (WITH
IGNITER)
SPARK TEST
1. Turn ignition switch ON.
2. Check that there is battery voltage at ignition coil positive (+)
terminal.
CHECK IF WIRE HARNESS SIDE CONNECTOR OF
IGNITION COIL (WITH IGNITER) IS SECUREConnect securely.
Check wiring between ignition switch to
ignition coil (with igniter).
NG
OK
OKNG
NG PERFORM SPARK TEST WITH A DIFFERENT
IGNITION COIL (WITH IGNITER)
1. Replace current ignition coil (with igniter) with a different,
functioning ignition coil (with igniter).
2. Perform spark test again.
OKIf sparks occur, replace faulty ignition coil
(with igniter).
NG
Continue on next page
Standard:ColdHot
1,060 to 1,645 W
OKNG
835 to 1,400 WReplace camshaft position sensor. CHECK RESISTANCE OF CAMSHAFT POSITION
SENSOR (See page 18-5)
- IGNITIONIGNITION SYSTEM (2AZ-FE)
18-1
2861 Author
: Date
:
IGNITION SYSTEM (2AZ-FE)
ON-VEHICLE INSPECTION
NOTICE:
In this section, the terms coldº and hotº refer to the temperature of the coils. ºColdºmeans approxi-
mately -10C (14F) to 50C (122F). ºHotº means approximately 50C (122F) to 100C (212F).
1. INSPECT IGNITION COIL ASSY (WITH IGNITER) AND PERFORM SPARK TEST
(a) Check for DTCs.
NOTICE:
If a DTC is present, perform a troubleshooting in accordance with the procedure for that DTC.
(b) Check if sparks occur.
(1) Remove the engine cover No. 1 (see page 14-24).
(2) Remove the ignition coils.
(3) Using a 16 mm (0.63 in.) plug wrench, remove the spark plugs.
(4) Install the spark plugs to each ignition coil and connect the ignition coil connectors.
(5) Disconnect the 4 injector connectors.
(6) Ground the spark plugs.
(7) Check if sparks occur at each spark plug while the engine is being cranked.
NOTICE:

Be sure to ground the spark plug when checking.

Replace the ignition coil if given physical impact is given to the coil.

Do not crank the engine for more than 2 seconds.
If the sparks do not occur, do the following test:

Replace crankshaft position sensor. CHECK RESISTANCE OF CRANKSHAFT POSITION
Standard:Cold Hot
985 to 1,600 W1,265 to 1,890 W
CHECK IGT SIGNAL FROM ECM
REPAIR WIRING BETWEEN IGNITION COIL AND ECM
OKNG
NG SENSOR (See page 18-6)
OK (See page 05-174)Check ECM (see page 05-32).
OK Continued from previous page 18-2
- IGNITIONIGNITION SYSTEM (2AZ-FE)
2862 Author
: Date
:
(8) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs.
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
(9) Install the ignition coils.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
(10) Install the engine cover No. 1.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)

100FS-06
10-12
- ENGINE CONTROL SYSTEMSFI SYSTEM (3MZ-FE)
2370 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
SFI SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
1. CHECK THROTTLE BODY
(a) Listen to the throttle control motor operating sounds.
(1) Turn the ignition switch ON.
(2) When pressing the accelerator pedal position sensor lever, listen to the running motor. Make sure
no friction noise comes from the motor.
If friction noise exists, replace the throttle body.
(b) Inspect the throttle position sensor.
(1) Connect the hand-held tester or OBD II scan tool to the DLC3.
(2) Turn the ignition switch ON.
(3) Check that the MIL is off.
(4) Under CURRENT DATA, the throttle valve opening percentage (THROTTLE POS) should be
within the standard value range below.
Standard throttle valve opening percentage:
60 % or more
If the percentage is less than 60 %, replace the throttle position sensor.
NOTICE:
When checking the standard throttle valve opening percentage, the transmission should be in the
neutral position.
2. CHECK ACCELERATOR PEDAL POSITION SENSOR
(a) Turn the ignition switch ON. Under CURRENT DATA, the voltage of the throttle position sensor should
be within the standard value range below.
Standard: 0.6 to 1.0 V
If the result is not as specified, replace the accelerator pedal position sensor.
3. CHECK CAMSHAFT TIMING OIL CONTROL VALVE (OCV) ASSY
(a) Connect the hand-held tester or OBD II scan tool to the DLC3.
(b) Turn the ignition switch ON.
(c) Start the engine and warm it up.
(d) Select the VVT from the ACTIVE TEST menu.
(e) Check the engine speed when the OCV is operated by the hand-held tester or OBD II scan tool.
Standard:
ConditionSpecified Condition
VVT system is OFF (OCV is OFF)Normal engine speed
VVT system is ON (OCV is ON)Rough idle or engine stalled
If the result is not as specified, replace the OCV assy.

2005 HIGHLANDER (EWD592U)
M
3
IK2 10
L- B
GRL- W
B- R
2
30 W
E
R
V
B- RD
5
IM1 5
R
1
BJ1 18B
5IO1
W- B
78
6 5
(
Cont. next page)
2 HIGHLANDER (
Cont' d)
E ngine C ontrol (
3MZ- FE)
29
STARTER Fuse
<1- 2>
Park/Neutral Posit ion SW
<1- 2>NS W STA
B B- R RSB
W- B
EB1
CCV
LE 27 1
2 B- W
B
Y
G
B- WP
R- W
W
B
Y
L A
B
D
G
VG
J
K E
L
M
N
O
P
QD 35E4EE32E1E 8A 10A20
THA 2A 1A
B- W
3AE E 16 E 17
W
Y
E2 G
G B- WWB YL2 1
2 1
2 1
6CE 15 34 E EB2 7B- W B- R B- R
BR- YG
33 D
W
A
B
C 21 6B
W+BM
W
RRL +B 2 +B B AT T
Air Conditioning Sys tem
<34- 8><35- 8>B 2
B- R
B- R
W- L2B- R
E R- W
GR
Y- GBR
8C
L- W
8E
R- L
9E
P10 E
Y- B11 E
L- Y12 E
G- Y13 E
L- R
I gnit ion Coil and I gniter s
<1- 3><1- 4> E
FAN NO. 2 Relay
<32- 3>
MREL FC #60 #50 #40 #30 #20 #10ACMG CF IGT1 IGT2 IGT3 IGT4 IGT5 IGT6 ACMACI S PRG HT2 B
Charging Sy stem
<1- 5>
11 IK21
29 D
BOX 2B3(
Shielded)
4 B- W CW W
C
IO1 16 F
BJ1 14
GR
1
B- W
STP
19 B
Electronically Controlled Transmission
and A/T I ndic ator Sys tem
<13- 2>
27 D 35 D 26 D 34 D
Elec tr onic ally
Controlled
Transmission and
A/T Indicator System
<13- 5>
NT- NT+ NC+ NC-
IGF1
Ignition Coil and Igniters
<1- 3> W- RE 24 GR
W
B- R B- R B- RGR
B- R B- W
9A
IGSW 12 B
ST 1-E E
HEE
P
2
1
Stop Light
System< 9- 1>SB
I11 AW4F BR
BR
P
PVP
4 3
14 IM1
W
V 5
S15 V1 4
J 3
H 6
V 4
V 2
M 1FAN NO. 1 Relay
<32- 3>
E 5(
A)
, E 6(
B)
, E 7(
E)
, E 8(
D)
, E 9(
C)
Engine Cont rol Module
Heated Ox ygen Sensor
(
Bank 2 Sensor 2)
Junction
Connector
Mass Air Flow Meter
Stop Light SW VSV (
ACIS No. 2) VSV (
EVAP)
VSV (
ACM) VSV
(
Canis ter Closed Valve)
E2 +B +B E1
VG E2G THA
HT OX

2005 HIGHLANDER (EWD592U)
M OVERALL ELECTRICAL WIRING DIAGRAM
1
W- BW- BG- B L
BJ1 VTA1 VCVTA2 E2
12
BRBI1 13 IM1
3M- M+12
IM1
1112
10 9
(
Cont. next page)
2 HIGHLANDER (
Cont' d)
E ngine C ontrol (
3MZ- FE)
E(
Shielded) R- W
GR B
C
12
IO1 3 D
6
25 D 21 D24 13
BRB
R- Y
VTA2 VC18 E 315D 22D A20 13 24D
D 3EB1
30 D 4 D 23 D D31 13 24 6EB1
17 C 3 C 21 E2 1
19 E 21 A C
2 1 16 C 15 C
2 1 14 C 13 C 4 W- B
B- WBRY
GRWB- R
YA
B
D
E
PLL
HT1B OX1B HA1H A1A+ A1A- HA2A A2A+ A2A- TC 2
G- WG- RL- R G- B
W
G- R G- B
OC2+ GE01 M+ VTA1 THW PTNK
OC 1+ OC 1 - OC2 - E(
Shielded)
(
Shielded) O
O
BRR- W
5
B- R R- W
IM1 (
Shielded)
6
M-IM1 3
(
Shielded)
W
F AW
(
Shielded)
BJ 1 16
3BI1IO1 15
2IM1
BR G- RBYL
WB R- WB- R Y
WB R- WB- RY3 Y
1 W- B
2 BR BR
1 22 C
EC Left Side of the
Cylinder Head7E 6E
Y- B W- B W- BMOPS E01 E02
1 10 CPSW
R- W
(
Shielded)
C
12 A
Voltage Inv ert er
< 27- 4>ELS2G
DMulti- Display
<30- 6>
R- W R- W
W- BIO17
PL
17 BJ1
BR2BI1Y
O
FBR
5A
5B
E 28
E2
BR BR BRR- W
BR
BR
4C
W- BME01
W- B (
*1)
(
*2)
* 2 : w/ Rear Seat Ent ert ainment Sys tem * 1 : w/ Navigation Syst em
O 1
P 2 E 2
V11
S28(
A)
, S29(
B)
T13
A 7
A 6
H10 J16
E 5(
A)
, E 6(
B)
, E 7(
E)
, E 8(
D)
, E 9(
C)
C 3
C 4 Air Fuel Ratio Sens or
(
Bank 1 Sens or 1) Air Fuel Ratio Sens or
(
Bank 2 Sens or 1)
C amsh af t Ti mi ng Oi l
Control Valve LH
C amsh af t Ti mi ng Oi l
Control Valve RH
Engine Coolant
Temp. Sensor
Engine Contr ol Module
Heat ed Oxy gen Sens or
(
Bank 1 Sensor 2) Junction
Connec tor
Oil Pressure SW
Power Steering Oil
Pressure SW
Short Connector
Throttle Control Motor
Vapor Press ur e Sens orVCC GND PTNK+B E2
+B AF- +B AF-
AF + HT AF+ HT OX 1B HT1B Thrott le Posit ion Sensor

2005 HIGHLANDER (EWD592U)
M
1516
14 13
(
Cont. next page)
2 HIGHLANDER (
Cont' d)
(
Shielded)
(
Shielded)
(
Shielded) O
E ngine C ontrol (
3MZ- FE)
A
B
D
E
ED Rear Side of
Cylinder Head6D 7D 26 C 25 C C24 27 CIM1
A A
A
A
A
AA
A
A
L R R GL B- W
(
Shielded) (
Shielded) (
Shielded)VV2+ NE+ NE- VV1+ EKN2(
Shielded)
(
Shielded)
(
Shielded)
(
Shielded)
(
Shielded)BR
(
Shielded)
BR RR
7C
W- B W- B
W- B
W- BE03 E05 E04B
D O
R
BR
G
G C
(
Shielded)
D28D 1 20 D 2D1EA1 2 3 EA1 4EA1
KNK2 KNK1 EKNKEA1
W
B
G
R R GB W
C W- B
F
B
G A
5ATACH
18 ASIL
19 AWFSE
E
R V
R
B
15 A
EOM
W- B
A W
30 AENG-
25 ATRC+
31 ATRC-
17 ANE O
R Y GB
24 AENG+
V
Skid Control ECU
wit h Act uat or
<15- 5> FW
1 2
1 2
2 1
26 A 22 A 28 A 27 A 23 A 29 A
VCPA VPA EPA VCP2 VPA2 EPA2 EPA2 YPA2 VCP2 EPA VPA VCPA
231564
BRWL R
B G Elec tronic ally Cont rolled
Transmis sion and A/T
Indicator System< 13- 4>
D 10 B 17 B
YSPD 9IL2Y
CANCEL
- SET
+R E S
ON - OFF
LG
24 BCCS
Cruise Control (
3M Z- FE)
26 BIMO
V
27 BIMI
B Combination Meter
< 31- 4>
29 B 18 BMPX1 MPX2
Multiplex Communication
Sy st em (
BEAN Bus)
< 20- 3>
1 2
1 2
V
(
Shielded)
1E
E1
BR
A
A4
17 IM1 BRBR
5 4
OLG Cr uis e Cont rol SW
K 3
V 7
C 7
V 6
J 7
A27
K 2C1 6
E 5(
A)
, E 6(
B)
, E 7(
E)
, E 8(
D)
, E 9(
C)Accel Position SensorCrankshaft
Pos ition Sens orCombinat ion SWEngine Contr ol ModuleJunct ion
Connect or
Knock Sens or
(
Ba nk 1)
Knock Sens or
(
Ba nk 2)
VVT Sens or LH VVT Sens or RH
Transponder Key Computer
<4- 3>

2005 HIGHLANDER (EWD592U)
M OVERALL ELECTRICAL WIRING DIAGRAM
1920
18 17
2 HIGHLANDER (
Cont' d)
Cruise Control (
3M Z- FE)
4L A
A
Sk id Cont rol ECU with Ac tuator
<15- 6><15- 12>
W
B
W14
PPR
4L 6 12 4A 7
GF
B RSIL
11
OCA NL
6 CA NH
12TS
21 IL2GR
W- B
R C
D
SC BATTC 51613
4F 5
R W
OB
VV
B
B 15WFSE
E4G 1TAC
9
B
B
B
Sk i d Con t ro l ECU wi t h Ac t u at o r
<15- 6>
54I
4M 14G5
1E 3
1L 3
BR W
A
7 4N 14L
ICRight Cowl Side Panel
W- B
4H 5W- B
W- B
64C4CG
V O W
A
Occupant Classification ECU
<16- 12>
V BR
PCombination Meter
<31- 3>
Airbag Sensor
Assembly< 16- 9> V
Tr ansponder Key Comput er
<4- 3>
1E 12Body ECU
<18- 3> O W- B
J16D 3
Data Link Connect or 3
Junction
Connector