TOYOTA HIGHLANDER 2001 Service Repair Manual

I40608
Combination Meter Assy
Wire Harness View: ECM Wire Harness View:
C12-1
E5-5
I40144
E5-5 ECM Wire Harness View:
05-1892
- DIAGNOSTICSCOMBINATION METER
2082 Author
: Date
:
5 CHECK HARNESS AND CONNECTOR(ECM - COMBINATION METER ASSY)
(SEE PAGE 01-26)
(a) Disconnect the C12 and E5 connectors.
(b) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionConditionSpecified Condition
C12-1 - E5-5AlwaysBelow 1 W
C12-1 - Body groundAlways10 kW or higher
NG REPAIR OR REPLACE HARNESS AND
CONNECTOR
OK
6 INSPECT COMBINATION METER ASSY
(a) Disconnect the E5 connector.
(b) Measure the voltage according to the value(s) in the table
below.
Standard:
Tester ConnectionConditionSpecified Condition
E5-5 - Body groundIgnition switch ON10 to 14 V
NG REPLACE COMBINATION METER ASSY
(SEE PAGE 71-18)
OK
GO TO ENGINE CONTROL SYSTEM(SEE PAGE 05-5, 05-366)

I44266
ECM
E2
THW E719 E728
BR
G-BBR*1
1
2 5
S29 S285
E2
Engine
Coolant
Temp Sensor Short ConnectorC11
Combination Meter Assy
BEANMPX- 21
*1: 2AZ-FE
*2: 3MZ-FEW-B*2 BR
05-1896
- DIAGNOSTICSCOMBINATION METER
2086 Author
: Date
:
MALFUNCTION IN WATER TEMPERATURE RECEIVER GAUGE
WIRING DIAGRAM
INSPECTION PROCEDURE
HINT:
If there is an open or short in the engine coolant temperature sensor circuit, the ECM outputs DTCs. Perform
troubleshooting with the ºSFI System 05-5,.05-366º.
1 PERFORM ACTIVE TEST BY HAND-HELD TESTER
(a) Operate the hand-held tester according to the steps on the display and select the ºACTIVE TESTº.
METER:
ItemTest DetailsDiagnostic Note
COOLANT TEMPLOW / NORMAL / HI-
OK:
Needle indication is normal.
NG REPLACE COMBINATION METER ASSY
(SEE PAGE 71-18)
OK
05IQ0-05

- DIAGNOSTICSCOMBINATION METER
05-1897
2087 Author
: Date
:
2 READ VALUE OF HAND-HELD TESTER(ENGINE COOLANT)
(a) Operate the hand-held tester according to the steps on the display and select the ºDATA LISTº.
ECM:
ItemMeasurement Item/
Range (Display)Normal ConditionDiagnostic Note
COOLANT TEMPCoolant Temperature / Min.: -40
C
(-40°F), Max.: 140
C (284°F)After warming up: 80 to 95°C (176
to 203°F)If the value is º-40
C (-40°F)º or
º140
C (284°F)º, sensor circuit is
open or shorted.
OK:
Coolant temperature displayed on the tester is between 80
C (176
F) and 95
C (203
F) after
warning up.
NG GO TO ENGINE CONTROL SYSTEM
(SEE PAGE 05-5, 05-366)
OK
3 REPLACE COMBINATION METER ASSY
OK:
Normal operation
NG GO TO ENGINE CONTROL SYSTEM
(SEE PAGE 05-5, 05-366)
OK
END

0305U-04
6N
8N
10N
11 N
12N
B06432
Nut Type
Present Standard
Hexagon Nut
Cold Forging Nut Cutting Processed NutClass
4N
5N (4T)
6N
7N (5T)
8N
10N (7T)
11 N
12N Old Standard Hexagon Nut
No Mark (w/ Washer)No Mark
*
No Mark (w/ Washer)
No Mark
No Mark
*: Nut with 1 or more marks on one side surface of the nut.
- SERVICE SPECIFICATIONSSTANDARD BOLT
03-3
124 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
HOW TO DETERMINE NUT STRENGTH
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more

160Q2-03
A73603
16-32
- COOLINGRADIATOR ASSY (3MZ-FE)
2818 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
RADIATOR ASSY (3MZ-FE)
ON-VEHICLE CLEANING
1. INSPECT FINS BLOCKAGE
(a) If the fins are clogged, wash them with water or a steam
cleaner. Dry with compressed air.
NOTICE:

If the distance between the steam cleaner and the
core is too close, the fins may become damaged.
Keep the following injection distance.
Standard:
DistanceSteam Cleaner Pressures
300 mm (11.81 in.)2,942 to 4,903 kPa
(30 to 50 kgf/cm2, 427 to 711 psi)
500 mm (19.69 in.)4,903 to 7,845 kPa
(50 to 80 kgf/cm2, 711 to 1,138 psi)

If the fins are bent, straighten them with a screwdriver
or pliers.

Never apply water directly onto the electronic compo-
nents.

18091-05
CHECK POWER SUPPLY TO IGNITION COIL (WITH
IGNITER)
SPARK TEST
1. Turn ignition switch ON.
2. Check that there is battery voltage at ignition coil positive (+)
terminal.
CHECK IF WIRE HARNESS SIDE CONNECTOR OF
IGNITION COIL (WITH IGNITER) IS SECUREConnect securely.
Check wiring between ignition switch to
ignition coil (with igniter).
NG
OK
OKNG
NG PERFORM SPARK TEST WITH A DIFFERENT
IGNITION COIL (WITH IGNITER)
1. Replace current ignition coil (with igniter) with a different,
functioning ignition coil (with igniter).
2. Perform spark test again.
OKIf sparks occur, replace faulty ignition coil
(with igniter).
NG
Continue on next page
Standard:ColdHot
1,060 to 1,645 W
OKNG
835 to 1,400 WReplace camshaft position sensor. CHECK RESISTANCE OF CAMSHAFT POSITION
SENSOR (See page 18-5)
- IGNITIONIGNITION SYSTEM (2AZ-FE)
18-1
2861 Author
: Date
:
IGNITION SYSTEM (2AZ-FE)
ON-VEHICLE INSPECTION
NOTICE:
In this section, the terms coldº and hotº refer to the temperature of the coils. ºColdºmeans approxi-
mately -10C (14F) to 50C (122F). ºHotº means approximately 50C (122F) to 100C (212F).
1. INSPECT IGNITION COIL ASSY (WITH IGNITER) AND PERFORM SPARK TEST
(a) Check for DTCs.
NOTICE:
If a DTC is present, perform a troubleshooting in accordance with the procedure for that DTC.
(b) Check if sparks occur.
(1) Remove the engine cover No. 1 (see page 14-24).
(2) Remove the ignition coils.
(3) Using a 16 mm (0.63 in.) plug wrench, remove the spark plugs.
(4) Install the spark plugs to each ignition coil and connect the ignition coil connectors.
(5) Disconnect the 4 injector connectors.
(6) Ground the spark plugs.
(7) Check if sparks occur at each spark plug while the engine is being cranked.
NOTICE:

Be sure to ground the spark plug when checking.

Replace the ignition coil if given physical impact is given to the coil.

Do not crank the engine for more than 2 seconds.
If the sparks do not occur, do the following test:

Replace crankshaft position sensor. CHECK RESISTANCE OF CRANKSHAFT POSITION
Standard:Cold Hot
985 to 1,600 W1,265 to 1,890 W
CHECK IGT SIGNAL FROM ECM
REPAIR WIRING BETWEEN IGNITION COIL AND ECM
OKNG
NG SENSOR (See page 18-6)
OK (See page 05-174)Check ECM (see page 05-32).
OK Continued from previous page 18-2
- IGNITIONIGNITION SYSTEM (2AZ-FE)
2862 Author
: Date
:
(8) Using a 16 mm (0.63 in.) plug wrench, install the spark plugs.
Torque: 19 NVm (194 kgfVcm, 14 ftVlbf)
(9) Install the ignition coils.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
(10) Install the engine cover No. 1.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)

100FS-06
10-12
- ENGINE CONTROL SYSTEMSFI SYSTEM (3MZ-FE)
2370 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
SFI SYSTEM (3MZ-FE)
ON-VEHICLE INSPECTION
1. CHECK THROTTLE BODY
(a) Listen to the throttle control motor operating sounds.
(1) Turn the ignition switch ON.
(2) When pressing the accelerator pedal position sensor lever, listen to the running motor. Make sure
no friction noise comes from the motor.
If friction noise exists, replace the throttle body.
(b) Inspect the throttle position sensor.
(1) Connect the hand-held tester or OBD II scan tool to the DLC3.
(2) Turn the ignition switch ON.
(3) Check that the MIL is off.
(4) Under CURRENT DATA, the throttle valve opening percentage (THROTTLE POS) should be
within the standard value range below.
Standard throttle valve opening percentage:
60 % or more
If the percentage is less than 60 %, replace the throttle position sensor.
NOTICE:
When checking the standard throttle valve opening percentage, the transmission should be in the
neutral position.
2. CHECK ACCELERATOR PEDAL POSITION SENSOR
(a) Turn the ignition switch ON. Under CURRENT DATA, the voltage of the throttle position sensor should
be within the standard value range below.
Standard: 0.6 to 1.0 V
If the result is not as specified, replace the accelerator pedal position sensor.
3. CHECK CAMSHAFT TIMING OIL CONTROL VALVE (OCV) ASSY
(a) Connect the hand-held tester or OBD II scan tool to the DLC3.
(b) Turn the ignition switch ON.
(c) Start the engine and warm it up.
(d) Select the VVT from the ACTIVE TEST menu.
(e) Check the engine speed when the OCV is operated by the hand-held tester or OBD II scan tool.
Standard:
ConditionSpecified Condition
VVT system is OFF (OCV is OFF)Normal engine speed
VVT system is ON (OCV is ON)Rough idle or engine stalled
If the result is not as specified, replace the OCV assy.

2005 HIGHLANDER (EWD592U)
M OVERALL ELECTRICAL WIRING DIAGRAM
34
2 1
1 HIGHLANDER
2ACC
IG1
IG2
ST2 AM1 4
Engine Cont rol Module
<2- 8><3- 6><3- 7> 6
8 7AM2
W- R(
*1)
B
W1C 6
1A 1
10
Engine Cont rol
Module< 2- 7> < 3- 6>
140A ALT2
W- R W- R 2 1
3 5
22
1A
B1N P
41F 6
W- R 1C 4
EFLeft Side of
Cy linder Block 1IC3 1
W- R STARTER
Relay
42 42 42 42 42 42 13 13 13 13 13 13
BB
GR
B- WW L- Y
W- B W- B W- B W- B RRRRR(
*1)
WYORR R- L(
*1) R P R Y- BR L- Y R(
*1) G- Y(
*1) R(
*1) L- R(
*1)
W- B W- R W- B W- R W- B W- R W- B W- R W- B(
*1) W- G(
*1) W- B(
*1) W- R(
*1)
W- B
BRW- R W- R
Starting and Ignition Power Source
15A IG2
40A AM1
12
1
EC Left Side of
the Cylinder Head 2 2 2IC1 1IC1
30A AM2
2 2
7. 5 A ST ARTER
3W
4 EB13 EB2
L
Engine Contr ol
Module< 2- 6> < 3- 8>
FL MAIN
3. 0W W- RB- R
B- W
1
1C1
1G GR
* 1 : 3MZ- FE
* 2 : 2AZ- FE
W- B
(
*1) (
*2)
1
2
(
*1)
(
*1) G
Under the
Left HeadlightEH A ST1
3IC1 B 1BB-Y
P 1
5 4 EB2
B- R
L- W
B
Engine Control
Module<2- 6><3- 8>B- R
BB
B- WW- B
2EB1
BRW- R
R- W(
*2)
4A
4BA
B
C
(
Cont. next page)
W
W
G
I15
J 2 F 7
S 1(
A)
, S 2(
B)
S28(
A)
, S29(
B)
I 2 I 3 I 4 I 5 I 6 I 7
N 1
Fusible Link Block
Ignition Coil and
Igniter No. 1 Ignition Coil and
Igniter No. 2 Ignition Coil and
Igniter No. 3 Ignition Coil and
Igniter No. 4 Ignition Coil and
Igniter No. 5 Ignition Coil and
Igniter No. 6
Ignition SW
Junc tion
Connec tor
Noise Filt er
(
Ignition System)
Park/Neutral
Position SW
Starter
Short Connector GND IGF GND IGF I GFGND GND IGF IGFGN D GN D I GF +B IGT +B IGT I GT+B +B I GT I GT+B +B I GT

2005 HIGHLANDER (EWD592U)
M
78
6 5
1 HIGHLANDER (
Cont' d)
4A
L
1 A
2 A
1 B S
IG
B1B 51C 7
8EB2
W- LR W
R- B 10A ECU- IG
Charging
2H 12I 1
7. 5A ALT- S
10 EB2
W- L WG
W- LR
A
B
C
1K 13
10 A HEAT ER
111
BCh ar g e
3B 12
3K 2
IBRi g ht I ns t r u me nt
Panel Br aceRBR
21 C 29 B 18 B
Multiplex Communication
System (
BEAN Bus)
<20- 3>
RL MPX2 MPX1
W- G3C 7 3A 4
P
W
W
G
E 6(
B)
, E 9(
C)
C11
G 1(
A)
, G 2(
B)
Combination Meter
Engine Cont rol Module
Ge ne r at or