TOYOTA HIGHLANDER 2001 Service Repair Manual

Z17005
Fig. 2
Sensor
C
BA
ECU
1
21
22 1
B04722
Fig. 3
Sensor
B2
A
1
21
2
21
C
B1
1
2ECU
Z17007
Fig. 4
Sensor
CBA
1
21
2
2 15V
5V
0V 01-38
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
38 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(b) Check the resistance.
(1) Disconnect connectors A and C and measure the
resistance between them.
Resistance: Below 1 W
HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.
Fig. 2:
Tester ConnectionSpecified Condition
Connector A terminal 1 -
Connector C terminal 110 kW or higher
Connector A terminal 2 -
Connector C terminal 2Below 1 kW
If your results match the examples above, an open circuit exists
between terminal 1 of connector A and terminal 1 of connector
C.
(2) Disconnect connector B and measure the resis-
tance between the connectors.
Fig. 3:
Tester ConnectionSpecified Condition
Connector A terminal 1 -
Connector B1 terminal 1Below 1 kW
Connector B2 terminal 1 -
Connector C terminal 110 kW or higher
If your results match the examples above, an open circuit exists
between terminal 1 of connector B2 and terminal 1 of connector
C.
(c) Check the voltage.
(1) In a circuit in which voltage is applied to the ECU
connector terminal, an open circuit can be checked
by conducting a voltage check.
Fig. 4:
With each connector still connected, measure the
voltage between the body ground these terminals
(in this order): 1) terminal 1 of connector A at the
ECU 5V output terminal, 2) terminal 1 of connector
B, and 3) terminal 1 of connector C.

Z17008
CSHORT
1
2B
1
21
2 A
Fig. 5
Z17009
Fig. 6
Sensor
C
BA
ECU
1
21
22 1
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01-39
39 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(2) Example results:
Tester ConnectionSpecified Condition
Connector A terminal 1 -
Body ground5 V
Connector B terminal 1 -
Body ground5 V
Connector C terminal 1 -
Body ground0 V
If your results match the examples above, an open circuit exists
in the wire harness between terminal 1 of B and terminal 1 of
C.
3. CHECK SHORT CIRCUIT
(a) If the wire harness is ground shorted (Fig. 5), locate the
section by conducting a resistance check with the body
ground (below).
(b) Check the resistance with the body ground.
(1) Disconnect connectors A and C and measure the
resistance between terminals 1 and 2 of connector
A and the body ground.
Resistance: 10 kW or higher
HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.
Fig. 6:
Tester ConnectionSpecified Condition
Connector A terminal 1 -
Body groundBelow 1 kW
Connector A terminal 2 -
Connector C terminal 210 kW or higher
If your results match the examples above, a short circuit exists
between terminal 1 of connector A and terminal 1 of connector
C.

Z17808
Fig. 7
Sensor
B2
A
11 1
C
B1
1ECU
2
222
IN0383
Example
Ground
IN0384
Ground ECU Side
W/H Side
Ground
01-40- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
40 Author
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:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(2) Disconnect connector B and measure the resis-
tance between terminal 1 of connector A and the
body ground, and terminal 1 of connector B2 and
the body ground.
Fig. 7:
Tester ConnectionSpecified Condition
Connector A terminal 1 -
Body ground10 kW or higher
Connector B2 terminal 1 -
Body groundBelow 1 kW
If your results match the examples above, a short
circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE:

The connector should not be disconnected from the
ECU. Perform the inspection from the backside of the
connector on the wire harness side.

When no measuring condition is specified, perform
the inspection with the engine stopped and the igni-
tion switch ON.

Check that the connectors are fully seated. Check for
loose, corroded or broken wires.
(a) First check the ECU ground circuit. If it is faulty, repair it.
If it is normal, the ECU could be faulty. Replace the ECU
with a normal functioning one and check if the symptoms
occur. If the trouble symptoms stop, replace the ECU.
(1) Measure the resistance between the ECU ground
terminal and body ground.
Resistance: Below 1 W
(2) Disconnect the ECU connector. Check the ground
terminals (on the ECU side and wire harness side)
for evidence of bending, corrosion or foreign materi-
al. Lastly check the contact pressure of the female
terminals.

010QI-01
D25521
A
B
D25520
A
B
C
01-4
- INTRODUCTIONIDENTIFICATION INFORMATION
4 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND SERIAL NUMBERS
1. VEHICLE IDENTIFICATION NUMBER
(a) The vehicle identification number is stamped on the ve-
hicle identification number plate and certification label, as
shown in the illustration.
A: Vehicle Identification Number Plate
B: Certification Label
2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL
NUMBER
(a) The engine serial number is stamped on the cylinder
block of the engine and the transmission serial number is
stamped on the housing as shown in the illustration.
A: 3MZ-FE
B: 2AZ-FE
C: U140E, U151E, U151F, U241E

010QL-02
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01-25
25 Author
: Date
:
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
A large number of ECU controlled systems are used in the HIGHLANDER. In general, ECU controlled sys-
tems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. How-
ever, most problem checking procedures only involve inspecting the ECU controlled system's circuits one
by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform
effective troubleshooting, accurate diagnoses and necessary repairs. Detailed information and trouble-
shooting procedures on major ECU controlled systems in this vehicle are outlined below:
SystemSee Page
1. SFI System (2AZ-FE)05-1
2. SFI System (3MZ-FE)05-362
3. Tire Pressure Warning System05-729
4. ABS with EBD & BA & TRAC & VSC System05-761
5. Electronic Controlled Automatic Transaxle [ECT] (U241E/U140F)05-876
6. Electronic Controlled Automatic Transaxle [ECT] (U151E/U151F)05-986
7. Air Conditioning System05-1 114
8. Supplement Restraint System05-1 194
9. Lighting System05-1526
10. Audio System05-161 1
11. Rear Seat Entertaiment System05-1690
12. Navigation System05-1749
13. Combination Meter05-1868
14. Power Window Control System05-1901
15. Power Door Lock Control System05-1934
16. Wireless Door Lock Control System05-1960
17. Sliding Roof System05-1974
18. Engine Immobiliser System05-1985
19. Theft Deterrent System05-2012
20. Multiplex Communication System05-2040
21. CAN Communication System05-2090
22. Cruise Control System05-2136
FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER

Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should
be read thoroughly.

If the scan tool or tester cannot communicate with the ECU controlled systems when you have con-
nected the cable of the tester to the DLC3 with the ignition switch and tester turned ON, there is a prob-
lem on the vehicle side or tester side.
(1) If communication is normal when the tester is connected to another vehicle, inspect the diagnosis
data link line (Bus
line) or ECU power circuit of the vehicle.
(2) If communication is still impossible when the tester is connected to another vehicle, the problem
is probably in the tester itself. So perform the Self Test procedures outlined in the Tester Opera-
tor 's Manual.

010QH-01
N17080
Filler Cap
Float
Reservoir Tank

Grommet
Clip
Slotted Spring Pin
: Specified torque

Non-reusable partCylinder
Piston
Push Rod
Washer
Snap Ring
Boot

Gasket
Lock Nut
Clevis Pin
Clevis
N´m (kgf´cm, ft´lbf)
12 (120, 9)
15 (155, 11)
- INTRODUCTIONHOW TO USE THIS MANUAL
01-1
1 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. GENERAL DESCRIPTION
(a) This manual is written in accordance with SAE J2008.
(b) Repair operations can be separated into 3 main processes:
1. Diagnosis
2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting
3. Final Inspection
(c) This manual explains the ºDiagnosisº (found in the ºDiagnosticsº section) and ºRemoving and Instal-
ling, Replacing, Disassembling, Installing and Checking, and Adjustingº. ºFinal Inspectionº is omitted.
(d) The following essential operations are not written in this manual. However, these operations must be
performed in actual situations.
(1) Operations with a jack or lift
(2) Cleaning of a removed part when necessary
(3) Visual check
2. INDEX
(a) An alphabetical INDEX section is provided at the end of the book as a reference to help you find the
item to be repaired.
3. PREPARATION
(a) Use of Special Service Tools (SST) and Special Service Materials (SSM) may be required, depending
on the repair situation. Be sure to use SST and SSM when they are required and follow the working
procedure properly. A list of SST and SSM is in the Preparation section of this manual.
4. REPAIR PROCEDURES
(a) A component illustration is placed under the title where necessary.
(b) Non-reusable parts, grease application areas, precoated parts and torque specifications are noted
in the component illustrations.
Example:

Illustration:
what to do and where
Component part No. Detailed text: how to perform task
Task heading: what you will be doing
Set part No.
INSTALL FRONT AXLE HUB BEARING
D31332
B80366
01-2
- INTRODUCTIONHOW TO USE THIS MANUAL
2 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) Torque specifications, grease application areas, and non-reusable parts are emphasized in the proce-
dures.
NOTICE:
There are cases where such information can only be explained by using an illustration. In these
cases, all the information such as torque, oil, etc. are described in the illustration.
(d) The installation procedures are the removal procedures in reverse order. However, only installation
procedures requiring additional information are included.
(e) Only items with key points are described in the text. What to do and other details are placed in illustra-
tions next to the text. Both the text and illustrations are accompanied by standard values and notices.
(f) Illustrations of similar vehicle models are sometimes used. In those cases, specific details may be dif-
ferent from the actual vehicle.
(g) Procedures are presented in a step-by-step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The explanation text tells how to perform the task. It also has information such as specifications
and warnings.
Example:
HINT:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
headings are easy to read and the text below the task heading provides detailed information. Important spec-
ifications and warnings are always written in bold type.
5. SERVICE SPECIFICATIONS
(a) SPECIFICATIONS are presented in bold-faced text throughout the manual. The specifications are
also found in the Service Specifications section for quick reference.
6. TERMS DEFINITION
CAUTIONPossibility of injury to you or other people.
NOTICEPossibility of damage to the components being repaired.
HINTProvides additional information to help you perform repairs.

- INTRODUCTIONHOW TO USE THIS MANUAL
01-3
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
7. SI UNIT
(a) The units used in this manual comply with the SI UNIT (International System of Units) standard. Units
from the metric system and the English system are also provided.
Example:
Torque:
30 NVm (310 kgfVcm, 22 ftVlbf)

010QK-02
D25523
Rubber Attachment
- INTRODUCTIONREPAIR INSTRUCTION
01-21
21 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
VEHICLE LIFT AND SUPPORT LOCATIONS
1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP THE VEHICLE
(a) The vehicle must be unloaded before jacking up the vehicle. Never jack up/lift up a heavily loaded ve-
hicle.
(b) When removing heavy equipment such as the engine and transmission, the center of gravity of the
vehicle may shift. To stabilize the vehicle: place a balance weight in a location where it will not roll or
shift; or use a mission jack to hold the jacking support.
2. NOTICE FOR USING 4 POST LIFTS
(a) Follow the safety procedures outlined in its instruction manual.
(b) Use precautionary measures to prevent the free wheel beam from damaging tires or wheels.
(c) Use wheel chocks to secure the vehicle.
3. NOTICE FOR USING JACK AND SAFETY STAND
(a) Work in a flat area using wheel chocks at all times.
(b) Use a safety stand with a rubber attachment, as shown
in the illustration.
(c) Apply the jack and rigid rack to the specified location on
the vehicle.
(d) When jacking up the front wheels, release the parking
brake and place wheel chocks only behind the rear
wheels. When jacking up the rear wheels, place wheel
chocks only in front of the front wheels.
(e) The jack should not be used without the rigid rack.
(f) When jacking up only the front wheels or only the rear wheels, place wheel chocks on both sides of
the wheels touching the ground.
(g) When lowering the vehicle with its front wheels jacked up, release the parking brake and place wheel
chocks only in front of the rear wheels. When lowering a vehicle with its rear wheels jacked up, place
wheel chocks only behind the front wheels.

D27508
: JACK POSITION
: SUPPORT POSITION, PANTOGRAPH JACK POSITION
: CENTER OF VEHICLE GRAVITY (unload condition)
1,080 mm
(42.52 in.)
1,110 mm
(43.70 in.)
Center of Wheel
Center of Wheel
2WD
4WD 01-22
- INTRODUCTIONREPAIR INSTRUCTION
22 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)