TOYOTA HIGHLANDER 2001 Service Repair Manual

2005 HIGHLANDER (EWD592U)
57
G
Connector Joining Wire Harness and Wire Harness
CodeJoining Wire Harness and Wire Harness (Connector Location)
BB1Rear Door No.1 LH Wire and Floor No.2 Wire (Left Center Pillar)
BC1Rear Door No.1 RH Wire and Floor Wire (Right Center Pillar)
BG1
BG2Back Door No.1 Wire and Floor No.2 Wire (Rear Left of the Roof)
BG3
()
BH1Floor No.2 Wire and Floor Wire (Near the Rear Side Marker Light RH)
BI1Floor No.4 Wire and Fuel Tank Wire (Right Side of Rear Floor Crossmember)
BJ1Floor Wire and Floor No.4 Wire (Right Side of Rear Floor Crossmember)
BK1Roof No 2 Wire and Floor Wire (Right Rear Quarter Panel)BK2Roof No.2 Wire and Floor Wire (Right Rear Quarter Panel)

2005 HIGHLANDER (EWD592U)
58
G ELECTRICAL WIRING ROUTING
: Location of Connector Joining Wire Harness and Wire Harness
[w/ Power Seat]
[w/o Power Seat]

2005 HIGHLANDER (EWD592U)
59
G
Connector Joining Wire Harness and Wire Harness
123
4561 2 3
4 5 6
9 12345
8 7 6
17 16 15 14 13 12 11 101 2 3 4 5
6 7 8 9
10 11 12 13 14 15 16 17
BL1GrayBM1
CodeJoining Wire Harness and Wire Harness (Connector Location)
BL1Floor Wire and Front Seat RH Wire (Under the Front Passenger's Seat)BM1Floor Wire and Front Seat RH Wire (Under the Front Passenger's Seat)

100IU-03
A93427N´m (kgf´cm, ft´lbf) : Specified torque
7.9 (81, 70 in.Vlbf)x 3
V-Bank Cover Sub-assy
Vacuum Hose
Air Cleaner Filter Element
Sub-assy Air Cleaner Cap Sub-assyMAF Meter
Connector Fuel Vapor Feed Hose Assy
Vacuum Hose
w/ Performance Rod:
Front Suspension Upper Brace Center
Spacer
80 (815, 59)
Spacer
x 2
x 2
80 (815, 59)
10-16
- ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (3MZ-FE)
2374 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
THROTTLE BODY ASSY (3MZ-FE)
COMPONENTS

A82430
Non-reusable part
N´m (kgf´cm, ft´lbf) : Specified torque
Gasket
Throttle Body Assy
Water By-pass Hose No. 2
Water By-pass Hose No. 3Throttle Control Motor &
Throttle Position Sensor
Connector
11 (112, 8)
- ENGINE CONTROL SYSTEMTHROTTLE BODY ASSY (3MZ-FE)
10-17
2375 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)

BODY PANEL REPLACEMENT
F16755
F16755A
REMOVALBP-23
COWL TOP TO APRON BRACE (ASSY)
REPLACEMENT

BODY PANEL REPLACEMENT
F16756
10 mm (0.39 in.) 20 mm (0.79 in.) BP-24
INSTALLATION

Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)

Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.

After welding, apply the polyurethane foam to the corresponding parts.

After welding, apply body sealer and under-coating to the corresponding parts.

After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.

05CCX-06
ABS & EBD & BA Check SheetInspector 's
Name:
Customer 's Name
Date Vehicle
Brought InProduction DateVIN
Licence Plate No.
Odometer Reading/ /
/ /
Date Problem First Occurred
Frequency Problem Occurs/ /
ContinuouslyIntermittently ( times a day)
ABS does not operate.
ABS does not operate efficiently.
ABS Warning Light
AbnormalRemains ONDoes not Come On
DTC Check1st Time
2nd TimeNormal System Code
Trouble Code (Code )
Symptomskm
miles
Brake Warning
Light Abnormal
(PKB released)Remains ONDoes not Come On
BA does not operate.
EBD does not operate.
STOP LIGHT SW
SYSTEM
Freeze Frame Data
#IG ON
VEHICLE SPDON
OFF
NO SYS
ABS
BA
FAIL SF
km/h
MPH Trouble Code (Code )
Normal System Code
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-763
953 Author
: Date
:
CUSTOMER PROBLEM ANALYSIS CHECK

Inspector 's
Name:
Customer 's Name
Date Vehicle
Brought InProduction DateVIN
Licence No.
Odometer Reading/ /
/ /
Date Problem First Occurred
Frequency Problem Occurs/ /
ContinuousIntermittent ( times a day)
TRAC does not operate. (Wheels spin when starting rapidly.)
DisplaysDoes not Display
DTC Check1st Time
2nd TimeNormal System Code
Trouble Code (Code )
Normal System CodeTrouble Code (Code )
Symptomskm
miles
Light Abnormal TRAC OFF Indicator
Light Abnormal SLIP Indicator
Remains ONDoes not Come On
Check Item
NormalTrouble Code (Code )
NormalTrouble Code (Code )
ABS Warning Light
Malfunction
Indicator Light TRAC & VSC Check Sheet
Remains ONDoes not Come On
VSC does not operate. (Wheels sideslip at the time of sharp turning.)
VSC Warning
Indicator Abnormal
Skid Control
Buzzer AbnormalDoes not SoundSounds
VSC/TRC OFF SW
SYSTEMFreeze Frame Data
SHIFT POSITION
YAW RATON
OFF
VSC/TRAC
P, NR
D
deg/s
VFAIL
23
4L
MAS CYL PRESS
THROTTLE
MAS PRESS GRADE
G (RIGHT&LEFT)
G (BACK&FORTH)
STEERING ANG
deg
deg
MPa/s
G
G 05-764
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
954 Author
: Date
:

051ZG-1 1
SFI SYSTEM Check Sheet
Customer's Name
Date Vehicle
Brought in
VIN
Production Date
Licence Plate No.Odometer Reading
km
miles
Problem Symptoms
Engine Does
Not Start
Difficult to
Start
Poor Idling
Poor
Driveability
Engine Stall
Other
Engine does not crankNo initial combustionNo complete combustion
Engine cranks slowly
Other
Incorrect first idleIdling rpm is abnormalHigh ( rpm)Low ( rpm)
Rough idling
Other
HesitationBackfireMuffler explosion (after-fire)Surging
Knocking
Other
Soon after startingAfter accelerator pedal depressed
After accelerator pedal released
During A/C operation
Shifting from N to D
Other
Date Problem
Occurred
Problem Frequency
Condition When
Problem Occurs
Weather
Engine Operation
Engine Temp. Place Outdoor
TemperatureConstant
Sometimes ( times per day/month)Once only
Other
Fine
CloudyRainySnowyVarious/Other
Hot
Warm Cool
HighwaySuburbsInner CityUphillDownhill
Rough road
Other
Cold
Warming upAfter Warming upAny temp.Other
Starting
Just after starting ( min.)IdlingRacing
Driving
Constant speedAccelerationDeceleration
A/C switch ON/OFF
Other
Condition of Malfunction Indicator Lamp
(MIL)Remains onSometimes lights up Does not light up
Normal Malfunction code(s) (code )
Freeze frame data ( )
NormalMalfunction code(s) (code )
Freeze frame data ( )
Normal Mode
(Pre-check)
Check Mode DTC InspectionInspector's
Name
Cold (approx.
C/
F)
05-8
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
198 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
CUSTOMER PROBLEM ANALYSIS CHECK