TOYOTA HIGHLANDER 2001 Service Repair Manual

A90291
A67445
A92643
EFI Relay Wire Harness Side
E5
ECM
MREL
Engine Room J/B
05-316
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
506 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
9 CHECK WIRE HARNESS (EFI RELAY - ECM, EFI RELAY - BODY GROUND)
(a) Check the wire harness between the EFI relay and ECM.
(1) Remove the EFI relay from the engine room J/B.
(2) Disconnect the E5 ECM connector.
(3) Measure the resistance of the wire harness side
connectors.
Standard:
Tester ConnectionSpecified Condition
J/B EFI relay terminal 1 - E5-8 (MREL)Below 1 W
J/B EFI relay terminal 1 or E5-8 (MREL) - Body ground10 kW or higher
(b) Check the wire harness between the EFI relay and body
ground.
(1) Remove the EFI relay from the engine room J/B.
(2) Measure the resistance of the wire harness side
connector and the body ground.
Standard:
Tester ConnectionSpecified Condition
J/B EFI relay terminal 2 - Body groundBelow 1 W
OK REPAIR OR REPLACE HARNESS AND
CONNECTOR
NG
CHECK AND REPAIR HARNESS AND CONNECTOR (TERMINAL +B OF ECM - BATTERY POS-
ITIVE TERMINAL)

G30835G32449
E4
Electronically Controlled
Transmission Pattern Select SW
*
SNOW B9 15Multiplex Network
Body ECU
(*) Pattern Select Switch (ECT SNOW Switch)
When the ECT SNOW switch is pushed, the switch contact is made and the ECT SNOW mode is selected.
To cancel the ECT SNOW mode, push the ECT SNOW switch once again. The ECT SNOW mode is automati-
cally cancelled when the ignition switch is turned ºOFFº.Y
3 4 W-B
3D Center J/B
8
3F 13
W-B
IB
- DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U241E/U140F)05-983
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PATTERN SELECT SWITCH CIRCUIT
CIRCUIT DESCRIPTION
Multiplex network body ECU receives pattern select switch information, and sends it through the multiplex
communication system to the ECM.
ECT SNOW is the system that operates the throttle motor to control engine output to reduce skidding of the
driving wheels, guarantee takeoff acceleration, driving straightness and turning stability.
WIRING DIAGRAM
05ITR-02

G23382
Wire Harness Side:
(Connector Front View):
E4
C82813D25463
Switch Side:
(Connector Front View):
E4
05-984- DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U241E/U140F)
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
INSPECTION PROCEDURE
1 DRIVING TEST
(a) Start the engine.
(b) Turn the ECT SNOW switch ºOFFº (Normal drive mode).
(c) Confirm vehicle response by driving from a parked position to fully depressing the accelerator pedal.
(d) Turn the ECT SNOW switch ºONº and perform the same check as (c).
Confirm that there is a difference between ECT SNOW switch ºONº and ºOFFº.
HINT:

Driving test should be done on a paved road (a nonskid road).

Make sure not to use the TRAC system when testing a vehicle equipped with one.
OK:
There is a difference in acceleration between ºONº and ºOFFº.
NG Go to step 2
OK
PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE
(SEE PAGE 05-904)
2 CHECK HARNESS AND CONNECTOR(PATTERN SELECT SWITCH ASSY NO.1 -
BODY GROUND)
(a) Disconnect the connector of pattern select switch (ECT
SNOW switch).
(b) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSpecified Condition
4 - Body groundBelow 1 W
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR (SEE PAGE 01-36)
OK
3 INSPECT PATTERN SELECT SWITCH ASSY NO.1
(a) Measure the resistance according to the value(s) in the
table below.
Standard:
Switch ConditionTester ConnectionSpecified Condition
Press continuously
Pattern select switch
34
Below 1 W
Release
Pattern select switch3 - 4
10 kW or higher
NG REPLACE PATTERN SELECT SWITCH ASSY
NO.1
OK

G32072
B9
B9
SNOW
Multiplex Network Body ECU:
Back Side:
- DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U241E/U140F)05-985
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
4 CHECK HARNESS AND CONNECTOR(PATTERN SELECT SWITCH ASSY NO.1 -
MULTIPLEX NETWORK BODY ECU)
(a) Connect the connector of pattern select switch (ECT
SNOW switch).
(b) Disconnect the multiplex network body ECU connector.
(c) Measure the resistance between terminals SNOW of mul-
tiplex network body ECU and body ground.
Standard:
Switch ConditionTester ConnectionSpecified Condition
Press continuously
Pattern select switch
B9 - 15 (SNOW) - Below 1 W
Release
Pattern select switch
B9 15 (SNOW)
Body ground
10 kW or higher
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR (SEE PAGE 01-36)
OK
PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE
(SEE PAGE 05-904)

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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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
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
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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
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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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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