transmission TOYOTA HIGHLANDER 2001 Service Repair Manual

3 2 1 45678
9 1 0 111 21 31 41 51 6
DLC3
A04550
- DIAGNOSTICSAIR CONDITIONING SYSTEM
05-1 121
1311 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
7. CHECK DLC3
(a) The vehicle's ECM uses ISO 9141-2 for communication.
The terminal arrangement of the DLC3 complies with
SAEJ1962 and matches the ISO 9141-2 format.
Terminal No.Connection/Voltage or ResistanceCondition
7Bus + Line/Pulse generationDuring transmission
4Chassis Ground - Body Ground/1 W or lessAlways
5Signal Ground - Body Ground/1 W or lessAlways
16Battery Positive - Body Ground/9 to 14 VAlways
8. DATA LIST
HINT:
From the DATA LIST displayed on the hand-held tester, you can read the values of the displays, sensors,
actuators and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is
one way to shorten labor time.
(a) Connect the hand-held tester to the DLC3.
(b) Turn the ignition switch to the ON position.
(c) From the display on the tester, select the ºDATA LISTº.
ALL:
ItemMeasurement Item / Display
(Range)Normal ConditionDiagnostic Note
A/C SIGA/C signal / ON or OFFA/C ON: ON-
A C:
ItemMeasurement Item/Display
(Range)Normal ConditionDiagnostic Note
ROOM TEMP
Room temperature sensor
/min.: -6.5C (20.3F)
max.: 57.25C (135.05F)
Actual room temperature-
AMBI TEMP SENS
Ambient temperature sensor
/min.: -23.3C (-9.94F)
max.: 65.95C (150.71F)
Actual ambient temperature-
AMBI TEMP
Adjusted ambient temperature
/min.: -30.8C (-23.44F)
max.: 50.8C (123.44F)
Actual ambient temperature-
EVAP TEMP
Evaporator temperature sensor
/min.: -29.7C (-21.46F)
max.: 59.55C (139.19F)
Actual evaporator temperature-
SOLAR SENS-DSolar sensor (Driver side)
/min.: 0 max.: 255Changes depending on brightness
(Driver side)-
COOLANT TEMP
Engine coolant temperature
/min.: 1.3C (34.34F)
max.: 90.55C (194.99F)
Actual engine coolant temperature-
SET TEMP-D
Set temperature
(Driver side)
/min.: 0 max.: 255Actual set temperature
(Driver side)-
A/M DAMP POS-D
Air mix damper position
(Driver side)
/min.: -14% max.: 113.5%Changes depending on the set
temperature (Driver side)-

71-2
- INSTRUMENT PANEL/METERCOMBINATION METER
3593 Author
: Date
:
MAINT REQD indicator ia blinking or cotinuously illuminated.1. Resetting procedure
2. Combination Meter Assy71-3
71-18
All buzzer (key reminder, tail cancel, Seat belt) does not operate.1. Refer to troubleshooting
2. Combination Meter Assy05-1879
71-18
O/D OFF indicator light does not come on.
1. O/D off Select Switch
2. Wire Harness or Connector
3. Combination Meter Assy-
-
71-18
SLIP indicator light does not come on.
1. Wire Harness or Connector
2. Skid Control ECU
3. Combination Meter Assy-
05-761
71-18
VSC indicator light does not come on.
1. Wire Harness or Connector
2. Skid Control ECU
3. Combination Meter Assy-
05-761
71-18
TRC/TRAC OFF indicator light does not come on.
1. Wire Harness or Connector
2. Skid Control ECU
3. Combination Meter Assy-
05-761
71-18
A/T OIL TEMP indicator light does not come on.
1. Wire Harness or Connector
2. Automatic transmission
3. Combination Meter Assy-
05-883
05-993
71-18
ECT SNOW indicator light does not come on.
1. Wire Harness or Connector
2. ECM
3. Combination Meter Assy-
05-5
05-366
71-18
A/T shift indicator light does not come on.
1. Park Neutral Position Switch
2. Wire Harness or Connector
3. ECM
4. Combination Meter Assy05-883
05-993
-
05-5
05-366
71-18
ºCRUISEº indicator light does not come on.
1. Wire Harness or Connector
2. ECM
3. Combination Meter Assy-
05-5
05-366
71-18
Meter Gauges:
SymptomSuspect AreaSee page
Speedometer does not operate.1. Refer to troubleshooting05-1885
Tachometer does not operate.1. Refer to troubleshooting05-1889
Fuel Gauge does not operate or operates abnormally.1. Refer to troubleshooting05-1893
Water temperature does not operate.1. Refer to troubleshooting05-1896
Clock:
SymptomSuspect AreaSee page
Clock will not operate
Clock loses or gains time
1. Power source or ground
2. Integration control & panel assy05-1 170
05-1 173
05-1 175
71-6

2005 HIGHLANDER (EWD592U)
60
H SYSTEM CIRCUITS
2005 HIGHLANDER
ELECTRICAL WIRING DIAGRAM
SYSTEM CIRCUITS
Page
Air Conditioning (Automatic A/C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
298
Air Conditioning (Manual A/C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Audio System (6 Speaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Audio System (8 Speaker) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
Automatic Glare-Resistant EC Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Automatic Light Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Back-Up Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Combination Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Cruise Control (2AZ-FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Cruise Control (3MZ-FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Door Lock Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Electronically Controlled Transmission and A/T Indicator (2AZ-FE) . . . . . . 110
Electronically Controlled Transmission and A/T Indicator (3MZ-FE) . . . . . . 102
Engine Control (2AZ-FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Engine Control (3MZ-FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Engine Immobilizer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Front Deicer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Front Fog Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Front Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Garage Door Opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Headlight (w/ Daytime Running Light) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Headlight (w/o Daytime Running Light) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Illumination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Interior Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Key Reminder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Light Auto Turn Off System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Mirror Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Moon Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Multiplex Communication System (BEAN Bus) . . . . . . . . . . . . . . . . . . . . . . . . . 258
Multiplex Communication System (CAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
Navigation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
Power Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Power Seat (Driver's Seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Power Seat (Front Passenger's Seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Power Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Radiator Fan and Condenser Fan (2AZ-FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Radiator Fan and Condenser Fan (3MZ-FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Rear Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Rear Window Defogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Rear Wiper and Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Remote Control Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Seat Belt Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

31050-02
C82977
No.2 Plug
No.1 Plug
Drain Plug
F45388
- TRANSFERTRANSFER ASSY (4WD)
31-9
3087 Author
: Date
:
TRANSFER ASSY (4WD)
OVERHAUL
HINT:
COMPONENT:
3MZ-FE ENGINE: See page 14-134
2AZ-FE ENGINE: See page 14-15
AUTOMATIC TRANSMISSION (U151E/U151F): See page 40-18
TRANSFER: See page 31-3
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE)
(SEE PAGE 14-149)
2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE)
(SEE PAGE 14-24)
3. REMOVE TRANSFER CASE NO.1 PLUG
(a) Remove the transfer case No.1 plug.
(b) Remove the gasket No.1 from the transfer case No.1
plug.
4. REMOVE TRANSFER CASE NO.2 PLUG
(a) Remove the transfer case No.2 plug.
(b) Remove the gasket No.2 from the transfer case No.2 plug.
5. REMOVE TRANSFER DRAIN PLUG
(a) Remove the transfer drain plug and bleed the transfer oil.
(b) Remove the drain gasket from the transfer drain plug.
6. REMOVE TRANSFER STIFFENER PLATE RH (2AZ-FE
ENGINE TYPE)
(a) Remove the 5 bolts and the stiffener plate RH.
7. REMOVE ENGINE MOUNTING BRACKET RR (2AZ-FE ENGINE TYPE)
(a) Remove the 3 bolts and the engine mounting bracket RR.
8. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE)
(SEE PAGE 40-20)

C82785
F45388
C82977
No.2 PlugNo.1 Plug
Drain Plug
- TRANSFERTRANSFER ASSY (4WD)
31-35
3113 Author
: Date
:
(b) Install the transfer assy to the transaxle assy with the 2
bolts and 6 nuts.
Torque: 69 NVm (700 kgfVcm, 51 ftVlbf)
NOTICE:

Check that the gasket is installed to the transfer assy
before instaling them to the transaxle assy.

Install the transfer assy to the transaxle assy without
tilting.

When moving the transfer assy, do not hold the oil
seal on the both sides.
83. INSTALL ENGINE MOUNTING BRACKET RR (2AZ-FE ENGINE TYPE)
(a) Install the engine mounting bracket RR with the 3 bolts.
Torque: 64 NVm (652 kgfVcm, 47 ftVlbf)
84. INSTALL TRANSFER STIFFENER PLATE RH (2AZ-FE
ENGINE TYPE)
(a) Install the stiffener plate RH with the 5 bolts.
Torque: 34 NVm (350 kgfVcm, 25 ftVlbf)
85. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE)
(SEE PAGE 40-20)
86. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149)
87. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24)
88. INSTALL TRANSFER DRAIN PLUG
(a) Install the transfer drain plug with a new drain gasket.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
89. INSTALL TRANSFER CASE NO.2 PLUG
(a) Install the transfer case No.2 plug with a new gasket No.2.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)
90. INSTALL TRANSFER CASE NO.1 PLUG
(a) Add oil up to 0 to 5 mm below the lower side of the plug
hole.
Oil quantity: 0.9 L (0.95 US qts, 0.79 lmp. qts)
HINT:
When adding oil, pour it slowly.
(b) Install the transfer case No.1 plug with a new gasket No.1.
Torque: 49 NVm (500 kgfVcm, 36 ftVlbf)

3100U-07
C50328C83630SST
C50353C83631
8.7 to 9.3 mm
(0.3425 to 0.3661 in.)SST
- TRANSFERTRANSFER CASE OIL SEAL (4WD)
31-7
3085 Author
: Date
:
TRANSFER CASE OIL SEAL (4WD)
REPLACEMENT
1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE)
(SEE PAGE 14-149)
2. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE)
(SEE PAGE 14-24)
3. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (2AZ-FE ENGINE TYPE)
(SEE PAGE 31-9)
4. REMOVE TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) (SEE PAGE 31-9)
5. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE)
(SEE PAGE 40-20)
6. REMOVE TRANSFER ASSY (SEE PAGE 31-9)
7. REMOVE CTR DIFFERENTIAL LOCK SLEEVE (SEE PAGE 31-9)
SST 09308-00010
8. REMOVE TRANSFER CASE OIL SEAL
(a) Using SST, remove the oil seal from the case.
SST 09308-00010
NOTICE:
Do not damage the oil-seal-fitted surface of the case.
9. INSTALL TRANSFER CASE OIL SEAL
(a) Using SST, drive a new oil seal into the case to the posi-
tion shown in the illustration.
SST 09387-00010, 09950-70010 (09951-07150)
NOTICE:
Do not install it obliquely.
(b) Apply small amount of MP grease to the oil seal lip.
10. INSTALL CTR DIFFERENTIAL LOCK SLEEVE (SEE PAGE 31-9)
SST 09950-60010 (09951-00610), 09950-70010 (09951-07150)
11. INSTALL TRANSFER ASSY (SEE PAGE 31-9)
12. INSTALL TRANSFER STIFFENER PLATE RH (2AZ-FE ENGINE TYPE) (SEE PAGE 31-9)
13. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (2AZ-FE ENGINE TYPE)
(SEE PAGE 31-9)
14. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (3MZ-FE ENGINE TYPE)
(SEE PAGE 40-20)
15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (3MZ-FE ENGINE TYPE) (SEE PAGE 14-149)
16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (2AZ-FE ENGINE TYPE) (SEE PAGE 14-24)