TOYOTA HIGHLANDER 2001 Service Repair Manual

I30899
Fuel Sender Gauge
Connector Front View:
I39224
F
EWarning
05-1894
- DIAGNOSTICSCOMBINATION METER
2084 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
2 READ VALUE OF HAND-HELD TESTER(FUEL GAUGE)
(a) Operate the hand-held tester according to the steps on the display and select the ºDATA LISTº.
METER:
ItemMeasurement Item/
Range (Display)Normal ConditionDiagnostic Note
FUEL GAUGEFuel input signal
Min.: 0, Max.: 255
Fuel gauge indicates (F): 48
Fuel gauge indicates (3/4): 93
Fuel gauge indicates (1/2): 148
Fuel gauge indicates (1/4): 188
Fuel gauge indicates (E): 206
-
OK:
Fuel input signal displayed on the tester is almost the same as Needle indication.
NG Go to step 3
OK
REPLACE COMBINATION METER ASSY(SEE PAGE 71-18)
3 INSPECT FUEL SENDER GAUGE ASSY
(a) Measure the voltage according to the value(s) in the table
below.
Standard:
Tester ConnectionConditionSpecified Condition
F20-1 - F20-3Ignition switch ACC or ONBelow 1 to 5 V
(b) Remove the fuel sender gauge assy.
(c) Connect the fuel sender gauge connector.
(d) Check that the float position is between E and F.
(e) Measure the voltage between the terminals 2 and 1 of
connector according to the value(s) in the table below.
Standard:
Float levelFloat position mm (in.)Voltage (V)
F-34.8 (-1.37)
3 (0.12)4.5 to 4.75
1/292.8 (3.65)
3 (0.12)1.41
1.61
Warning137.0 (5.39)
3 (0.12)0.20 to 0.45
NG REPLACE FUEL SENDER GAUGE ASSY
OK

I40609
F12
C11-9
Combination Meter Assy
Wire Harness View:
Fuel Sender Gauge Connector
Front View:
- DIAGNOSTICSCOMBINATION METER
05-1895
2085 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
4 CHECK HARNESS AND CONNECTOR(FUEL SENDER GAUGE ASSY -
COMBINATION METER ASSY)(SEE PAGE 01-26)
(a) Disconnect the F12 and C11 connectors.
(b) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionConditionSpecified Condition
C11-9 - F12-2AlwaysBelow 1 W
F12-3 - Body groundAlwaysBelow 1 W
F11-9 - Body groundAlways10 kW or higher
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
END

A90349
Battery FL
MainInstrument Panel J/B Assy
L-Y
1 11C1Passenger Side J/B
P
F7
FL Block Assy Y
Combination Meter IC1
E511 I15
Ignition
Switch
WECM
GR
10
AM2
W1G6
4M4
4E1
W
IG2
AM26
7
IL19
IL2 10 J6
J/C
E
E P
SB
L
C11SB
C12 13 4
MIL IGN
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-359
549 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
MIL CIRCUIT
CIRCUIT DESCRIPTION
The Malfunction Indicator Lamp (MIL) is used to indicate the ECM's detection of a vehicle malfunction.
The instrument panel IG2 fuse provides circuit power and the ECM provides the circuit ground that illumi-
nates the MIL.
MIL operations should be checked visually:
The MIL should be illuminated when the ignition is first turned ON. If the MIL is always ON or OFF, use the
hand-held tester or OBD II
scan tool and follow the procedures to determine the cause of problem.
WIRING DIAGRAM
05EW1-05

A67445
W
E5
ECM
05-360
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
550 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
INSPECTION PROCEDURE
HINT:
Troubleshoot each trouble symptom in accordance with the chart below.
MIL remains onStart inspection from step 1
MIL is not illuminatedStart inspection from step 3
1 CLEAR DTC
(a) Connect the hand-held tester or the OBD II scan tool to the DLC3.
(b) Turn the ignition switch ON and push the hand-held tester or the OBD II scan tool main switch ON.
(c) Read the DTC.
(d) Clear the DTC (see page 05-38).
(e) Check that the MIL is not illuminated.
OK: MIL is not illuminated
OK REPAIR CIRCUIT INDICATED BY OUTPUT DTC
(See page 05-48)
NG
2 CHECK WIRE HARNESS (CHECK FOR SHORT IN WIRE HARNESS)
(a) Disconnect the E5 ECM connector.
(b) Turn the ignition switch ON.
(c) Check that the MIL is not illuminated.
OK: MIL is not illuminated
OK REPLACE ECM (See page 10-9)
NG
CHECK AND REPLACE HARNESS AND CONNECTOR
3 CHECK THAT MIL IS ILLUMINATED
(a) Check that the MIL is illuminated when turning the ignition switch ON.
OK: MIL is illuminated
NG SYSTEM OK
NG

- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-361
551 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
4 INSPECT COMBINATION METER ASSY (MIL CIRCUIT)
(a) See the combination meter troubleshooting on page 05-1889.
NG REPAIR OR REPLACE BULB OR COMBINATION
METER ASSEMBLY
OK
CHECK AND REPAIR HARNESS AND CONNECTOR (COMBINATION METER - ECM)

05F2Y-05
D09299
05-892- DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U241E/U140F)
1082 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
MANUAL SHIFTING TEST
1. PERFORM MANUAL SHIFTING TEST
HINT:
By this test, it can be determined whether the trouble is within
the electrical circuit or is a mechanical problem in the transaxle.
(a) Disconnect the transmission wire connector.
(b) Inspect the manual driving operation.
Check that the shift and gear positions correspond to the
table below.
While driving, shift through the L, 2 and D positions.
Check that the gear change corresponds to the shift posi-
tion.
Shift PositionGear Position
D3rd
23rd
L3rd
RReverse
PPawl Lock
HINT:
If the gear positions of the L, 2 and D are difficult to distinguish,
do the following road test (see page 05-887).
If any abnormality is found in the above test, the problem is in
the transaxle itself.
(c) Connect the transmission wire connector.
(d) Clear the DTC (see page 05-912).

I39199
Multi-display Controller Sub-assy Radio Receiver Assy
TX1+
TX1- TX+
TX-
R2930 R2931
GRLG
IP119 IP19
L Y
R2310 R239 05-1864
- DIAGNOSTICSNAVIGATION SYSTEM
2054 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
AVC-LAN CIRCUIT (MULTI-DISPLA Y CONTROLLER SUB-ASSY -
RADIO RECEIVER ASSY
CIRCUIT DESCRIPTION
Each unit of the navigation system connected to AVC-LAN (communication bus) communicates by transfer-
ring the signals from each switch.
When +B short and GND short occur in this AVC-LAN, navigation system will not function normally as com-
munication is discontinued.
In AVC-LAN, multi-display becomes the communication master, and the radio receiver assy has enough
resistance necessary for transmitting the communication.
WIRING DIAGRAM
05IT9-02

I40222
TX1+ TX1-
R23
I34639
Multi-display Controller Sub-assy:
R29
TX+TX-
I40203
Radio Receive Assy:
R23
TX1+
TX1-
- DIAGNOSTICSNAVIGATION SYSTEM
05-1865
2055 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
INSPECTION PROCEDURE
1 INSPECT RADIO RECEIVER ASSY
(a) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester connectionConditionSpecified condition
TX1+ - TX1-Always60 to 80 W
NG REPLACE RADIO RECEIVER ASSY
(SEE PAGE 67-6)
OK
2 CHECK HARNESS AND CONNECTOR(MULTI-DISPLA Y CONTROLLER
SUB-ASSY - RADIO RECEIVER ASSY)
(a) Disconnect the connectors from the multi-display control-
ler sub-assy R29 and radio receiver assy R23.
(b) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester connectionConditionSpecified condition
TX+ - TX1+AlwaysBelow 1 W
TX- - TX1-AlwaysBelow 1 W
TX+ - Body groundAlways10 kW or higher
TX- - Body groundAlways10 kW or higher
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN DIAGNOSTIC TROUBLE CODE CHART
(SEE PAGE 05-1791)

I39187
Gateway ECU
Center J/B
Instrument Panel J/B
Passenger Side J/B
Instrument Panel J/B I15
IGNITION SW
F7
FL Block
Engine Room J/B
Center J/BIG
ACC
BATT
GNDCG RAD No.2IG1
ACC
IG1 AM1AM1
ALT
D.C.C
DOME
IB Battery FL MAINW-B W-B
W-B W
3F 13
3G6 3G5
G5 14G57 2A3
2I1
3 12 W43
2W
1C6
2
11A1V
IK312
V
4H6
4D11
V
IL211
LG L G
1C2 1C7
1J6 1K 10
W GR
3F9 3A8 3A 10
3F8 3D1 3I1
LG SBB
G58 G59 G52
B 05-1834
- DIAGNOSTICSNAVIGATION SYSTEM
2024 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
POWER SOURCE CIRCUIT (GATEWAY ECU)
CIRCUIT DESCRIPTION
This circuit provides power to the gateway ECU.
WIRING DIAGRAM
05ISY-02

I40180
G5
CG
GNDIG
BATT
ACC
- DIAGNOSTICSNAVIGATION SYSTEM
05-1835
2025 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
INSPECTION PROCEDURE
1 INSPECT GATEWAY ECU(BATT, ACC, IG, GND ,CG)
(a) Disconnect the gateway ECU connector G5.
(b) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester connectionConditionSpecified condition
GND - Body groundAlwaysBelow 1 W
CG - Body groundAlwaysBelow 1 W
(c) Measure the voltage according to the value(s) in the table
below.
Standard:
Tester connectionConditionSpecified condition
BATT - GND or CGAlways10 to 14 V
ACC - GND or CGIgnition SW ACC10 to 14 V
IG - GND or CGIgnition SW ON10 to 14 V
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN DIAGNOSTIC TROUBLE CODE CHART
(SEE PAGE 05-1791)