TOYOTA HIGHLANDER 2001 Service Repair Manual

F45158
GND
- DIAGNOSTICSTIRE PRESSURE WARNING SYSTEM
05-743
933 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
Wave form 2:
Reference
ItemCondition
TerminalENG- - GND1
Tool setting1 V / DIV, 0.5 ms / DIV
Vehicle conditionEngine idle speed

0304O-04
03-32
- SERVICE SPECIFICATIONSSTARTING & CHARGING
153 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
TORQUE SPECIFICATION
2AZ-FE
Part TightenedNVmkgfVcmftVlbf
Starter assy
Starter assy x Engine3737727
Starter wire x Terminal 30 of starter9.81007.0
Starter drive housing assy x Magnet switch assy7.57666 in.Vlbf
Starter commutator end frame assy x Starter drive housing assy6.06153 in.Vlbf
Lead wire of starter yoke x Terminal C of magnet switch assy101027.0
Battery clamp x Battery clamp bolt5.55649 in.Vlbf
Cable x Battery terminal3.53631 in.Vlbf
Generator assy (100A)
Generator assy x Engine M8
M1021
52214
53015
38
Generator wire x Generator assy9.81007.0
Generator rectifier end frame x Drive end frame assy5.85951 in.Vlbf
Generator brush holder assy x Generator rectifier end frame1.81816 in.Vlbf
Generator rear end cover x Generator rectifier end frame4.64741 in.Vlbf
Retainer plate x Drive end frame assy generator2.32320 in.Vlbf
Generator pulley x Generator rotor assy11 01,12281
Generator assy (130A)
Generator assy x Engine M8
M1021
52214
53015
38
Generator wire x Generator assy9.81007.0
Generator rectifier end frame x Drive end frame assy5.85951 in.Vlbf
Generator brush holder assy x Generator rectifier end frame1.81816 in.Vlbf
Generator rear end cover x Generator rectifier end frame4.64741 in.Vlbf
Retainer plate x Drive end frame assy generator2.32320 in.Vlbf
Generator pulley x Generator rotor assy11 01,12281
3MZ-FE
Part TightenedNVmkgfVcmftVlbf
Starter assy
Starter assy x Engine3737727
Starter wire x Terminal 30 of starter9.81007.0
Starter drive housing assy x Magnet switch assy7.57666 in.Vlbf
Starter commutator end frame assy x Starter drive housing assy6.06153 in.Vlbf
Lead wire of starter yoke x Terminal C of magnet switch assy101027.0
Battery clamp x Battery clamp bolt5.55649 in.Vlbf
Cable x Battery terminal3.53631 in.Vlbf
Generator assy (100A)
Generator assy x Generator bracket No. 25859243
Generator assy x Generator belt adjusting bar1818413
Generator wire x Generator assy9.81007.0
Generator rectifier end frame x Drive end frame assy5.85951 in.Vlbf
Generator brush holder assy x Generator rectifier end frame1.81816 in.Vlbf
Generator rear end cover x Generator rectifier end frame4.64741 in.Vlbf
Retainer plate x Drive end frame assy generator2.32320 in.Vlbf
Generator pulley x Generator rotor assy11 01,12281
Generator assy (130A)
Generator assy x Generator bracket No. 25859243
Generator assy x Generator belt adjusting bar1818413
Generator wire x Generator assy9.81007.0

- SERVICE SPECIFICATIONSSTARTING & CHARGING
03-33
154 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)Part TightenedftVlbf kgfVcm NVm
Generator rectifier end frame x Drive end frame assy5.85951 in.Vlbf
Generator brush holder assy x Generator rectifier end frame1.81816 in.Vlbf
Generator rear end cover x Generator rectifier end frame4.64741 in.Vlbf
Retainer plate x Drive end frame assy generator2.32320 in.Vlbf
Generator pulley x Generator rotor assy11 01,12281

F46300
1A 1C
3F 3J E5
E6IC4 S27
C11
IF3 E5 IC4 S27
E5 IC4 S27
E5 IC4 S27
E6 C12C11
S27 IC4 1C1K
3A3C
IB 1
2
45
67
8
9
13
17 1819
2122
23
24 25
2930 31
43 18
9
7
1
1
1
413 1
27 4
13 24 ECM
Skid Control ECU with Actuator
Combination Meter
Instrument Panel J/BCenter J/B
F7
FL Block I15
Ignition SW
Center J/B
FL MAIN
BatteryT6
Trac Off SW TRC-
ENG-
MPX
SystemTRAC
OFF
HEATER
AM1 IG1
ALT
CSW AM1 TRC+
ENG+
MPX2TRC-
ENG- TRC+
ENG+
B G
R
V
WYY-B
G-B
W-G
W-L
P
WW G
WB
L-R
W-B
W-B MPX1
(*1) (*1) (*1)
(*1)
*1 : 2WD
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-859
1049 Author
: Date
:
TRAC OFF INDICATOR LIGHT, TRAC OFF SWITCH CIRCUIT
CIRCUIT DESCRIPTION
The skid control ECU detects the track control main switch ON/OFF signal and turns the track off light on/off.
This is the TRAC control main switch. When the TRAC control switch is pressed, the TRAC control does not
operate and the TRAC OFF light comes on.
WIRING DIAGRAM
05H3X-03

F00052
4
1
T6
05-860
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
1050 Author
: Date
:
INSPECTION PROCEDURE
HINT:
Start the inspection from step 1 when using the hand-held tester and start from step 2 when not using the
hand-held tester.
1 PERFORM ACTIVE TEST BY HAND-HELD TESTER(TRAC OFF INDICATOR
LIGHT)
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine.
(c) Select the item ºTRAC OFF LIGHTº in the ACTIVE TEST and operate the TRAC OFF indicator light
on the hand-held tester.
ItemVehicle Condition / Test DetailsDiagnostic Note
VSC / TRAC OFF INDTurns VSC / TRAC OFF indicator ON / OFFObserve combination me-
ter
(d) Check that ºONº and ºOFFº of the TRAC OFF indicator light are indicated on the combination meter
when using the hand-held tester.
OK:
Turn the TRAC OFF indicator light on or off in accordance with the hand-held tester.
NG Go to step 6
OK
2 INSPECT TRACTION CONTROL SWITCH
(a) Remove the TRAC control switch.
(b) Disconnect the TRAC control switch connector T6.
(c) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSwitch ConditionSpecified Condition
T6 4 T6 1Pushed in (ON)Below 1 WT6-4 - T6-1Released (OFF)10 kW or higher
NG REPLACE TRACTION CONTROL SWITCH
OK

F46260
Skid Control ECU
(harness side connector)
TRAC Control Switch
(harness side connector)S27
E+ T6
CSW
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-861
1051 Author
: Date
:
3 CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - TRAC OFF
SWITCH)
(a) Disconnect the skid control ECU connector S27 and the
TRAC control switch connector T6.
(b) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSpecified Condition
S27-43 (CSW) - T6-4 (+)Below 1 W
S27-43 (CSW) - Body ground10 kW or higher
T6-1 (E) - Body groundBelow 1 W
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
4 INSPECT MULTIPLEX COMMUNCATION SYSTEM (SEE PAGE 05-2040)
NG REPAIR MULTIPLEX COMMUNCATION
SYSTEM
OK

F45165F44428F45165F44428F45351
ENG-
ENG+ENG-ENG+
Skid Control ECU
(harness side connector)
ECM
TRC+
TRC-
TRC+
TRC-S27
E5
05-862
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
1052 Author
: Date
:
5 CHECK HARNESS AND CONNECTOR(SKID CONTROL ECU - ECM)
(a) Disconnect the skid control ECU connector S27 and ECM
connector E5.
(b) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSpecified Condition
S27-8 (TRC+) - E5-25 (TRC+)
S27-22 (TRC-) - E5-31 (TRC-)Below 1WS27-9 (ENG+) - E5-24 (ENG+)Below 1 W
S27-23 (ENG-) - E5-30 (ENG-)
(c) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSpecified Condition
S27-8 (TRC+) - Body ground
S27-22 (TRC-) - Body ground10 kWor higherS27-9 (ENG+) - Body ground10 kW or higher
S27-23 (ENG-) - Body ground
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
6 INSPECT COMBINATION METER ASSEMBLY (SEE PAGE 05-1868)
NG REPAIR OR REPLACE COMBINATION METER
ASSEMBLY
OK
REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37)

To Ignition SW
IG Terminal
Fuse
Voltmeter SW 1
Relay
SW 2Solenoid[A]
[B]
[C]
Ohmmeter
SW
Ohmmeter
Diode
Digital Type Analog Type
2005 HIGHLANDER (EWD592U)
12
C TROUBLESHOOTING
VOLTAGE CHECK
(a)Establish conditions in which voltage is present at the check
point.
Example:
[A] - Ignition SW on
[B] - Ignition SW and SW 1 on
[C] - Ignition SW, SW 1 and Relay on (SW 2 off)
(b)Using a voltmeter, connect the negative lead to a good ground
point or negative battery terminal, and the positive lead to the
connector or component terminal.
This check can be done with a test light instead of a voltmeter.
CONTINUITY AND RESISTANCE CHECK
(a)Disconnect the battery terminal or wire so there is no voltage
between the check points.
(b)Contact the two leads of an ohmmeter to each of the check
points.
If the circuit has diodes, reverse the two leads and check
again.
When contacting the negative lead to the diode positive side
and the positive lead to the negative side, there should be
continuity.
When contacting the two leads in reverse, there should be no
continuity.
(c)Use a volt/ohmmeter with high impedance (10 kW/V
minimum) for troubleshooting of the electrical circuit.

To Ignition SW
IG Terminal
Test Light
Relay Light
SW 2 SolenoidDisconnectShort [A]
Disconnect
DisconnectSW 1Fuse Case
Short [B]
Short [C]
Pull Up
Press Down Press DownPull Up
2005 HIGHLANDER (EWD592U)
13
C
FINDING A SHORT CIRCUIT
(a)Remove the blown fuse and disconnect all loads of the fuse.
(b)Connect a test light in place of the fuse.
(c)Establish conditions in which the test light comes on.
Example:
[A] - Ignition SW on
[B] - Ignition SW and SW 1 on
[C] - Ignition SW, SW 1 and Relay on (Connect the
Relay) and SW 2 off (or Disconnect SW 2)
(d)Disconnect and reconnect the connectors while watching the
test light.
The short lies between the connector where the test light
stays lit and the connector where the light goes out.
(e)Find the exact location of the short by lightly shaking the
problem wire along the body.
CAUTION:
(a) Do not open the cover or the case of the ECU unless
absolutely necessary. (If the IC terminals are touched,
the IC may be destroyed by static electricity.)
(b) When replacing the internal mechanism (ECU part) of
the digital meter, be careful that no part of your body or
clothing comes in contact with the terminals of leads
from the IC, etc. of the replacement part (spare part).
DISCONNECTION OF MALE AND FEMALE
CONNECTORS
To pull apart the connectors, pull on the connector itself, not
the wire harness.
HINT : C h e c k t o s e e w h a t k i n d o f connector you are
disconnecting before pulling apart.

10
3
0.2
11
(mm) Reference:
Tool Up Example:
(Case 1)
Terminal Retainer
Terminal Retainer
[Retainer at Full Lock Position]
[Retainer at Temporary Lock Position]StopperTerminal
Retainer
Secondary
Locking Device Example:
(Case 2)
2005 HIGHLANDER (EWD592U)
14
C TROUBLESHOOTING
HOW TO REPLACE TERMINAL
(with terminal retainer or secondary locking device)
1.PREPARE THE SPECIAL TOOL
HINT : To remove the terminal from the connector, please
construct and use the special tool or like object shown on
the left.
2.DISCONNECT CONNECTOR
3.DISENGAGE THE SECONDARY LOCKING DEVICE OR
TERMINAL RETAINER.
(a)Locking device must be disengaged before the terminal
locking clip can be released and the terminal removed from
the connector.
(b)Use a special tool or the terminal pick to unlock the secondary
locking device or terminal retainer.
NOTICE:
Do not remove the terminal retainer from connector body.
[A] For Non-Waterproof Type Connector
HINT : The needle insertion position varies according to the
connector's shape (number of terminals etc.), so
check the position before inserting it.
ºCase 1º
Raise the terminal retainer up to the temporary lock
position.
ºCase 2º
Open the secondary locking device.