TOYOTA HIGHLANDER 2001 Service Repair Manual

A85255
Pressure Gauge
Pressure
B06546
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
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28 REPLACE FUEL TANK CAP ASSY
HINT:
When installing the fuel tank cap, tighten it until a few click sounds are heard.
NEXT Go to step 37
29 REPAIR EVAP LEAK PART
(a) Reinstall the fuel cap.
(b) Remove the exhaust tail pipe.
(c) Remove the heat insulator under the canister.
(d) Pinch the atmospheric side hose of the pump module with
the clip to close the canister's passage to air.
(e) Connect the pressure gauge (SST) to the service port
(green cap near the air cleaner box).
(f) Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28
mmHg).
NOTICE:
More than 35 mmHg of pressure will damage the EVAP sys-
tem. Pay attention to the pressure.
(g) Apply soapy water to the piping and connecting parts of
the EVAP system. Look for the area where bubbles ap-
pear. This area cause leaks.
HINT:

If the system has leaks, a whistling sound will be heard.

Disconnect the hose between canister and fuel tank from
the canister. Close the canister on the area where the
hose was connected and perform an inspection. The fuel
tank can be eliminated from the suspected areas for leak
checks.
(h) Repair or replace the leak point.
NEXT Go to step 37
30 REPLACE CHARCOAL CANISTER ASSY
NEXT Go to step 37

A85254
Purge VSV
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31 REPLACE VACUUM SWITCHING VALVE ASSY NO.1(PURGE VSV)
(a) Disconnect the connector and the hoses from the purge
VSV.
(b) Remove the purge VSV.
(c) Install a new purge VSV.
(d) Reconnect the connector and hoses.
NEXT Go to step 37
32 REPAIR OR REPLACE WIRE HARNESS AND CONNECTOR
In case that the exhaust tail pipe is removed, go to the next step before installing it.
NEXT Go to step 37
33 REPLACE EVAP HOSE(THROTTLE BODY - PURGE VSV)
NEXT Go to step 37
34 INSPECT THROTTLE BODY ASSY
(a) Remove the throttle body (see page 10-6).
(b) Check that there is no clog in the EVAP purge port of the throttle body. If necessary, replace the throttle
body.
NEXT Go to step 37
35 REPLACE ECM (see page 10-9)
NEXT Go to step 37
36 REPAIR OR REPLACE PARTS AND COMPONENTS INDICATED BY OUTPUT DTCS
(a) Repair the malfunctioning areas indicated by the DTCs that had been confirmed when the vehicle was
brought in.
NEXT Go to step 37

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37 PERFORM EVAP SYSTEM CHECK(AUTO OPERATION)
NOTICE:

In the EVAP SYSTEM CHECK (AUTO OPERATION), the series of 5 EVAP SYSTEM CHECK steps
is performed automatically. It takes a maximum of approximately 18 minutes.

Do not perform the EVAP SYSTEM CHECK when the fuel tank is more than 90% full because
the cut-off valve may be closed, making the leak check of the fuel tank unavailable.

Do not run the engine in this step.

When the temperature of the fuel is 35C (95F) or more, a large amount of vapor forms and any
check results become inaccurate. When performing an EVAP SYSTEM CHECK, keep the tem-
perature below 35C
(95F).
(a) Clear DTCs (see page 05-38).
(b) On the hand-held tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / SYS-
TEM CHECK / EVAP SYS CHECK / AUTO OPERATION.
(c) After the SYSTEM CHECK is completed, check for pending DTCs by selecting the following menu
items: DIAGNOSIS / ENHANCED OBD II / DTC INFO / PENDING CODES.
HINT:
If no pending DTC is found, the repair has been successfully completed.
NEXT
COMPLETED

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Monitor Confirmation
HINT:
After a repair, check Monitor Status by performing the Key-Off Monitor Confirmation and Purge Flow Monitor
Confirmation described below.
1. KEY-OFF MONITOR CONFIRMATION
(a) Preconditions
The monitor will not run unless:

The vehicle has been driven for 10 minutes or more (in a city area or on a free way)

The fuel tank is less than 90% full

The altitude is less than 8,000 ft (2,400 m)

The Engine Coolant Temperature (ECT) is between 4.4C and 35C (40F and 95F)

The Intake Air Temperature (IAT) is between 4.4C and 35C (40F and 95F)

The vehicle remains stationary (the vehicle speed is 0 mph [0 km/h])
(b) Monitor Conditions
(1) Allow the engine to idle for at least 5 minutes.
(2) Turn the ignition switch OFF and wait for 6 hours (8 or 10.5 hours).
HINT:
Do not start the engine until checking MONITOR STATUS. If the engine is started, the steps described above
must be repeated.
(c) Monitor Status
(1) Connect a hand-held tester to the DLC3.
(2) Turn the ignition switch ON and turn the tester ON.
(3) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR
STATUS.
(4) Check the Monitor Status displayed on the tester.
HINT:
If INCMP is displayed, the monitor is not completed. Make sure that the preconditions have been met, and
perform the Monitor Conditions again.
2. PURGE FLOW MONITOR CONFIRMATION (P0441)
HINT:
Perform this monitor confirmation after the Key-Off Monitor Confirmation shows COMPL (complete).
(a) Preconditions
The monitor will not run unless:

The vehicle has been driven for 10 minutes or more (in a city area or on a free way)

The ECT is between 4.4C and 35C (40F and 95F)

The IAT is between 4.4C and 35C (40F and 95F)
(b) Monitor Conditions
(1) Release the pressure from the fuel tank by removing and reinstalling the fuel tank cap.
(2) Warm the engine up until the ECT reaches more than 75C (167F).
(3) Increase the engine speed to 3,000 rpm once.
(4) Allow the engine to idle and turn A/C ON for 1 minute.
(c) Monitor Status
(1) Turn the ignition switch OFF (where ON or the engine is running).
(2) Connect a hand-held tester to the DLC3.
(3) Turn the ignition switch to ON and turn the tester ON.
(4) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR
STATUS.
(5) Check the Monitor Status displayed on the tester.

- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
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HINT:
If INCMP is displayed, the monitor is not completed. Make sure that the preconditions have been met, and
perform the Monitor Conditions again.
MONITOR RESULT
Refer to page 05-26 for detailed information.
The test value and test limit information are described as shown in the following table. Check the monitor
result and test values after performing the monitor drive pattern (Refer to ºConfirmation Monitorº).

TID (Test Identification Data) is assigned to each emissions-related component.

TLT (Test Limit Type):
If TLT is 0, the component is malfunctioning when the test value is higher than the test limit.
If TLT is 1, the component is malfunctioning when the test value is lower than the test limit.

CID (Component Identification Data) is assigned to each test value.

Unit Conversion is used to calculate the test value indicated on generic OBD ll scan tools.
(d) Key - off
TID $02: EVAP system (Key-off monitor)
TLTCIDUnit ConversionDescription of Test DataDescription of Test Limit
1$01Multiplied by 0.0156 subtract 2
(kPa)Test value for small leak (P0456):
Refer to pressure D*Malfunction criteria (0 kPa)
1$02Multiplied by 0.0156 subtract 2
(kPa)Test value for gross leak (P0455):
Refer to pressure E*Malfunction criteria (0 kPa)
1$03Multiplied by 0.0156 subtract 2
(kPa)Test value for vacuum pump stuck OFF
(P2401):
Refer to pressure A*
Malfunction criteria (0 kPa)
1$04Multiplied by 0.0156 subtract 2
(kPa)Test value for vacuum pump stuck ON
(P2402):
Refer to pressure A*
Malfunction criteria (0 kPa)
1$05Multiplied by 0.0156 subtract 2
(kPa)Test value for vent valve stuck OFF (vent)
(P2420):
Refer to pressure C*
Malfunction criteria (0 kPa)
1$06Multiplied by 0.0156 subtract 2
(kPa)Test value for vent valve stuck ON (closed)
(P2419):
Refer to pressure A*
Malfunction criteria (0 kPa)
1$07Multiplied by 0.0156 subtract 2
(kPa)Test value for 0.02 inch orifice low flow
(P043E):
Refer to pressure B*
Malfunction criteria (0 kPa)
1$08Multiplied by 0.0156 subtract 2
(kPa)Test value for 0.02 inch orifice high flow
(P043F):
Refer to pressure A*
Malfunction criteria (0 kPa)
1$11Multiplied by 0.0156 subtract 2
(kPa)Test value for purge VSV stuck close
(P0441):
Refer to pressure F*
Malfunction criteria (0 kPa)
1$12Multiplied by 0.0156 subtract 2
(kPa)Test value for purge VSV stuck open
(P0441):
Refer to pressure E*
Malfunction criteria (0 kPa)
1$13Multiplied by 0.0156 subtract 2
(kPa)Test value for purge flow (P0441):
Refer to pressure G*Malfunction criteria (0 kPa)
* Pressures A to G are indicated as shown in the diagram below.

G38136
Key-off Monitor
Purge VSV
Vent Valve
Atomosphere (0 kPa)
Criterion 1 (-1.2 kPa)
Criterion 5 (-4.3 kPa)
Elapsed Time (Seconds)
104EVAP Pressure
(Reference) PumpMonitor Start
ON (Open)
ON (Close)
ON
A
BC
60D
GWithin 720 Criterion 2 (Criterion 4 x 0.2)
Criterion 3 (0.3 kPa)
Criterion 4EF
Criterion 6 (0.3 kPa)
1060
Purge Flow Monitor
Sequence
Purge VSV
Vent Valve
Criterion 7 (0.1 kPa)
EVAP Pressure
(Reference)
Criterion 8 (1kPa)If pressure change in sequence 1 is
greater than criterion 7, purge flow moni-
tor is completed (functioning normally). ON (Close) 12
ON (Open)
If pressure change in sequence 1 is
smaller than criterion 7, sequence 2 is
run.
If pressure change in sequence 2 is
smaller than criterion 8, purge flow is in-
sufficient.
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05ESR-05
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FAIL-SAFE CHART
If any of the following codes are recorded, the ECM enters fail-safe mode.
DTC No.Fail-Safe OperationFail-Safe Deactivation Conditions
P0031
P0032
P0037
P0038
Turn off heaterIgnition switch OFF
P0100
P0102
P0103Ignition timing is calculated from engine speed and throttle
angleºPassº condition detected
P0110
P0112
P0113
Intake air temperature is fixed at 20°C (68°F)ºPassº condition detected
P0115
P0116
P0117
P0118
Engine coolant temperature is fixed at 80°C (176°F)ºPassº condition detected
P0120
P0121
P0122
P0123
P0220
P0222
P0223
P0604
P0606
P0607
P0657
P2102
P2103
P2111
P2112
P2118
P2119
P2135
If Electronic Throttle Control System (ETCS) has malfunc-
tion, ECM cuts off current to throttle control motor. Throttle
control valve returns to predetermined opening angle
(approximately 16
) by force of return spring. ECM then
adjusts engine output by controlling fuel injection (intermit-
tent fuel-cut) and ignition timing in accordance with acceler-
ator pedal opening angle to enable vehicle to continue at
minimal speed.
If accelerator pedal is depressed firmly and slowly, vehicle
can be driven slowly. If accelerator pedal is depressed
quickly, vehicle may speed up and slow down erratically.
ºPassº condition is detected and then ignition switch is turned
OFF, fail-safe operation will stop and system will return to
normal condition
P0325
P0327
P0328
Maximum timing retardationIgnition switch OFF
P0351
P0352
P0353
P0354
Fuel is cutºPassº condition detected
P2120
P2121
P2122
P2123
P2125
P2127
P2128
P2138Accelerator pedal position sensor has two (main and sub)
sensor circuits. If malfunction occurs in either of sensor
circuits, ECM detects abnormal signal voltage difference
between two sensor circuits and switches to limp mode. In
limp mode, remaining circuit is used to calculate accelerator
pedal opening to allow vehicle to continue driving.
If both circuits malfunction, ECM regards opening angle of
accelerator pedal to be fully closed. In this case, throttle
valve will remain closed as if engine is idling.
ºPassº condition is detected and then ignition switch is turned
OFF, fail-safe operation will stop and system will return to
normal condition

A90307
AM2
Main
StarterCircuit Opening Relay
PNP Switch ST1EFI Relay
ALT
Battery AM1ECM
NE STAMREL
IGSW EFI NO. 1
Ignition Switch
AM1
AM2Fuel Pump
ST2IG2IGN
(NE Signal) (STA Signal)FC
Tr
STARTER
STARTER
Relay
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
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FUEL PUMP CONTROL CIRCUIT
CIRCUIT DESCRIPTION
When the engine is cranked, current flows from the ignition switch terminal ST1 to the starter relay coil (Mark-
ing: STARTER), and current flows to terminal STA of the ECM (STA signal).
When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil of the circuit
opening relay, (Marking) the relay switches on, power is supplied to the fuel pump and the fuel pump oper-
ates.
While the NE signal is generated and the engine is running, the ECM keeps Tr ON (Circuit Opening relay
ON) and the fuel pump also keeps operating.
05EW0-05

A90308
IG2I15
Ignition Switch
FC MRELECM
Y8
E5
6
7
4 Engine
Room J/B
AM2
FL
Main
Battery
EHW-B IGN
IC1
2F
E510 IA2 32 51
1
3
5
2
3 10
1AM2
EFI
NO. 1EFI
Relay
W
F12
Fuel Pump
BCBR
8 F7
FL Block AssyCircuit
Opening
Relay B
L L-Y
W
W-B
J2
J/C A Y
1 11 1
52B
12I82B
1IK3
2
IC213
B WWW
P-L GRInstrument Panel J/B AssyPassenger Side J/B
R/B No.1 4M4
4F1
1G6
1C1
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WIRING DIAGRAM

B60778
5
12 312
5
3
A67446
FC (+)E1 (-)
E9
ECME5
ECM
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
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INSPECTION PROCEDURE
Hand-held tester:
1 PERFORM ACTIVE TEST USING HAND-HELD TESTER (OPERATE CIRCUIT
OPENING RELAY)
(a) Connect the hand-held tester to the DLC3.
(b) Turn ON the ignition switch. Push the hand-held tester main switch.
(c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD.
(d) Check the relay operation while operating it with the hand-held tester.
OK: Operating noise can be heard from the relay.
OK Go to step 5
NG
2 INSPECT CIRCUIT OPENING RELAY
(a) Remove the circuit opening relay from the R/B sub-assy.
(b) Measure the resistance of the circuit opening relay.
Standard:
Tester ConnectionSpecified Condition
3 - 510 kW or higher
3 - 5Below 1 W
(when battery voltage is applied to terminals 1 and 2)
NG REPLACE CIRCUIT OPENING RELAY
OK
3 INSPECT ECM (FC VOLTAGE)
(a) Turn the ignition switch ON.
(b) Measure the voltage of the ECM connectors.
Standard:
Tester ConnectionSpecified Condition
E5-10 (FC) - E9-1 (E1)9 to 14 V
OK REPLACE ECM (See page 10-9)
NG