engine TOYOTA HIGHLANDER 2001 Service Repair Manual

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- DIAGNOSTICSSFI SYSTEM (3MZ-FE)(From August, 2004)
600 Author
: Date
:
Hand-held Tester DisplayDiagnostic Note Normal Condition * Measurement Item/Range
(Display)
EVAP VSVVSV status for EVAP control/
ON or OFFVSV operating: ONEVAP VSV is controlled by the
ECM (ground side duty control)
BOOST PRESS VSV
VSV status for boost pressure
control/
ON or OFF
VSV operating: ON'
IGNITIONIgnition counter/ Minimum: 0, Max-
imum: 6000 to 600'
CYL #1, #2, #3, #4, #5, #6Misfire ratio of cylinder 1 to 6/
Minimum: 0 %, Maximum: 50 %0 %This item is displayed in only idling
MISFIRE LOAD
Engine load for first misfire range/
Minimum: 0 g/rev, Maximum: 3.98
g/rev.
Misfire 0: 0 g/rev.'
MISFIRE RPM
Engine RPM for first misfire range/
Minimum: 0 rpm, Maximum: 6,375
rpm
Misfire 0: 0 rpm'
FC TAUFuel Cut TAU: Fuel cut during very
light load/ ON or OFFFuel cut operating: ON
Fuel cut is being performed under
very light load to prevent engine
combustion from becoming incom-
plete
CHECK MODECheck mode/ ON or OFFCheck mode ON: ONSee step 3
HINT:
*: If no conditions are specifically stated for ºldlingº, the shift lever is in the N or P position, the A/C switch
is OFF and all accessory switches are OFF.
2. ACTIVE TEST
HINT:
Performing the hand-held tester ACTIVE TEST allows relay, VSV, actuator and other items to be operated
without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to shorten
labor time. The DATA LIST can be displayed during the ACTIVE TEST.
(a) Warm up the engine.
(b) Turn the ignition switch OFF.
(c) Connect the hand-held tester or the OBD II scan tool to the DLC3.
(d) Turn the ignition switch ON.
(e) Turn ON the hand-held tester or the OBD II scan tool.
(f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST.
(g) According to the display on tester, perform the ºACTIVE TESTº.
Hand-held Tester DisplayTest DetailsDiagnostic Note
INJ VOL
[Test Details]
Control injection volume
Minimum: -12.5 %, Maximum: 25 %
[Vehicle Condition]
Engine speed: 3,000 rpm or less
All injectors are tested at once

Injection volume is gradually
changed between -12.5 and 25
%
A/F CONTROL
[Test Details]
Control injection volume
-12.5 or 25 % (change injection volume -12.5 % or 25 %)
[Vehicle Condition]
Engine speed: 3,000 rpm or less
Following A/F CONTROL proce-
dure enables technician to check
and graph voltage outputs of both
the A/F sensor and heated oxygen
sensor
For displaying graph, enter ºAC-
TIVE TEST / A/F CONTROL /
USER DATAº, select ºAFS B1S1
and O2S B1S2º by pressing ºYESº
and push ºENTERº. Then press
ºF4º

- DIAGNOSTICSSFI SYSTEM (3MZ-FE)(From August, 2004)
05-41 1
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Hand-held Tester DisplayDiagnostic Note Test Details
INTAKE CTL VSV1
[Test Details]
Activate VSV for intake control
ON or OFF
'
CAN CTRL VSV
[Test Details]
Activate VSV for canister control
ON or OFF
'
EVAP VSV (ALONE)
[Test Details]
Activate EVAP VSV control
ON or OFF
'
A/C MAG CLUTCH
[Test Details]
Control A/C magnet clutch
ON or OFF
'
FUEL PUMP / SPD
[Test Details]
Control the fuel pump
ON or OFF
'
VVT CTRL B1
[Test Details]
Active VVT system (bank 1)
ON or OFF
ON: Rough idle or engine stall

OFF: Normal engine speed
VVT CTRL B2
[Test Details]
Active VVT system (bank 2)
ON or OFF
ON: Rough idle or engine stall

OFF: Normal engine speed
ACM INHIBIT
[Test Details]
Control ACM inhibit
ON or OFF
'
TC/TE1
[Test Details]
Connect TC and TE1
ON or OFF
'
FC IDL PROHBT
[Test Details]
Control idle fuel cut prohibit
ON or OFF
'

P
A90343
A80017
A91474
Engine Room J/B
ETCS EFI NO. 1
Engine Room R/B No. 2
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-39
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
3. CLEAR DTC (Not using the OBD II scan tool or hand-
held tester)
(a) Remove the EFI NO. 1 fuse from the engine room J/B and
ETCS fuse from the engine room R/B No. 2 for more than
60 seconds. Or, disconnect the battery terminal for more
than 60 seconds.
After disconnecting the battery cable, perform the ºINI-
TIALIZEº procedure (see page 05-893).

A90306
I15
Ignition
Switch
EE W-BIK2 AM2IGN1 Instrument Panel J/B Assy
E5
E9ECM
BatteryFL
MainEFI
NO. 1
4
W9
1 4E
1
E5
1 10GR
3
21 5EFI Relay
EHBR
BR AAP
Engine Room J/B
J7
J/C 2FIGSW
+B
E1 B EJ6
J/C
MRELE58
P-LE P 4
4M 6
1G 1
1CPassenger Side J/B
W
J2
J/C A W1
2I4
2B
5
2BW
W 10
IK313 IC1 1AM2 IG2
F7
FL Block AssyY
L-Y6
7
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
ECM POWER SOURCE CIRCUIT
CIRCUIT DESCRIPTION
When the ignition switch is turned ON, battery voltage is applied to terminal IGSW of the ECM. The ECM
ºMRELº output signal causes current to flow to the coil, closing the contacts of the EFI relay (Marking: EFI)
and supplying power to terminal +B of the ECM.
If the ignition switch is turned OFF, the ECM holds the EFI relay ON for a maximum of 2 seconds to allow
for the initial setting of the throttle valve.
WIRING DIAGRAM
05EVZ-05

A90343
Engine Room J/B
EFI NO. 1 fuse
B60778
5
1
2 312
5
3
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
7 CHECK FUSE (EFI NO. 1)
(a) Remove the EFI NO. 1 fuse from the engine room J/B.
(b) Measure the resistance of the EFI NO. 1 fuse.
Standard: Below 1 W
NG REPLACE FUSE
OK
8 INSPECT RELAY (EFI)
(a) Remove the EFI relay from the engine room J/B.
(b) Measure the resistance of the EFI relay.
Standard:
Tester ConnectionSpecified Condition
3 - 510 kW or higher
3 - 5Below 1 W
(when battery voltage is applied to terminals 1 and 2)
NG REPLACE RELAY
OK

A90291
A67445
A92643
EFI Relay Wire Harness Side
E5
ECM
MREL
Engine Room J/B
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
9 CHECK WIRE HARNESS (EFI RELAY - ECM, EFI RELAY - BODY GROUND)
(a) Check the wire harness between the EFI relay and ECM.
(1) Remove the EFI relay from the engine room J/B.
(2) Disconnect the E5 ECM connector.
(3) Measure the resistance of the wire harness side
connectors.
Standard:
Tester ConnectionSpecified Condition
J/B EFI relay terminal 1 - E5-8 (MREL)Below 1 W
J/B EFI relay terminal 1 or E5-8 (MREL) - Body ground10 kW or higher
(b) Check the wire harness between the EFI relay and body
ground.
(1) Remove the EFI relay from the engine room J/B.
(2) Measure the resistance of the wire harness side
connector and the body ground.
Standard:
Tester ConnectionSpecified Condition
J/B EFI relay terminal 2 - Body groundBelow 1 W
OK REPAIR OR REPLACE HARNESS AND
CONNECTOR
NG
CHECK AND REPAIR HARNESS AND CONNECTOR (TERMINAL +B OF ECM - BATTERY POS-
ITIVE TERMINAL)

G30835G32449
E4
Electronically Controlled
Transmission Pattern Select SW
*
SNOW B9 15Multiplex Network
Body ECU
(*) Pattern Select Switch (ECT SNOW Switch)
When the ECT SNOW switch is pushed, the switch contact is made and the ECT SNOW mode is selected.
To cancel the ECT SNOW mode, push the ECT SNOW switch once again. The ECT SNOW mode is automati-
cally cancelled when the ignition switch is turned ºOFFº.Y
3 4 W-B
3D Center J/B
8
3F 13
W-B
IB
- DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U241E/U140F)05-983
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
PATTERN SELECT SWITCH CIRCUIT
CIRCUIT DESCRIPTION
Multiplex network body ECU receives pattern select switch information, and sends it through the multiplex
communication system to the ECM.
ECT SNOW is the system that operates the throttle motor to control engine output to reduce skidding of the
driving wheels, guarantee takeoff acceleration, driving straightness and turning stability.
WIRING DIAGRAM
05ITR-02

G23382
Wire Harness Side:
(Connector Front View):
E4
C82813D25463
Switch Side:
(Connector Front View):
E4
05-984- DIAGNOSTICSELECTRONIC CONTROLLED AUTOMATIC
TRANSAXLE [ECT] (U241E/U140F)
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
INSPECTION PROCEDURE
1 DRIVING TEST
(a) Start the engine.
(b) Turn the ECT SNOW switch ºOFFº (Normal drive mode).
(c) Confirm vehicle response by driving from a parked position to fully depressing the accelerator pedal.
(d) Turn the ECT SNOW switch ºONº and perform the same check as (c).
Confirm that there is a difference between ECT SNOW switch ºONº and ºOFFº.
HINT:

Driving test should be done on a paved road (a nonskid road).

Make sure not to use the TRAC system when testing a vehicle equipped with one.
OK:
There is a difference in acceleration between ºONº and ºOFFº.
NG Go to step 2
OK
PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE
(SEE PAGE 05-904)
2 CHECK HARNESS AND CONNECTOR(PATTERN SELECT SWITCH ASSY NO.1 -
BODY GROUND)
(a) Disconnect the connector of pattern select switch (ECT
SNOW switch).
(b) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester ConnectionSpecified Condition
4 - Body groundBelow 1 W
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR (SEE PAGE 01-36)
OK
3 INSPECT PATTERN SELECT SWITCH ASSY NO.1
(a) Measure the resistance according to the value(s) in the
table below.
Standard:
Switch ConditionTester ConnectionSpecified Condition
Press continuously
Pattern select switch
34
Below 1 W
Release
Pattern select switch3 - 4
10 kW or higher
NG REPLACE PATTERN SELECT SWITCH ASSY
NO.1
OK

A93865Purge VSV
EVAP Hose
(To Throttle Body)
EVAP Hose
(From Canister)
Vent ValveCanister
Air Filter
Pump ModulePressure Sensor
Vacuum Pump
Purge Line
Refueling Valve
Fuel Tank
Fuel Cap
Location of EVAP (Evaporative Emission) system:
A93866
EVAP System Circuit
Intake Manifold
Purge VSV
Cut-of f Valve Roll-over Valve
CanisterAir FilterFuel Cap
Service Port
Air Cleaner
Restrictor (0.08 inch)
Refueling Valve Throttle Valve
ECM
Soak Timer
Pump Module (refer to fig. 1)
Fuel Tank 05-318
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CIRCUIT DESCRIPTION
While the engine is running, if a predetermined condition (closed-loop, etc.) is met, the purge VSV is opened
by the ECM and stored fuel vapors in the canister are purged to the intake manifold. The ECM changes the
duty cycle ratio of the purge VSV to control purge flow volume.
The purge flow volume is also determined by the intake manifold pressure.
Atmospheric pressure is allowed
into the canister through the vent valve to ensure that the purge flow is maintained when the negative pres-
sure (vacuum) is applied to the canister.
The following two monitors run to confirm appropriate EVAP system operation.

A97610
EVAP Purge Flow:
Canister Purge VSV
(ON)
Vacuum Pump (OFF)Air Filter Fuel Tank fuel tank cap
To Intake Manifold
Pump Module
Pressure Sensor0.02 Inch Orifice
Vent Valve (OFF)
ECM
Soak Timer
Refueling Valve
To Atmosphere
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
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Key-off monitor
This monitor checks for EVAP (Evaporative Emission) system leaks and pump module malfunctions. The
monitor starts 5 hours*
after the ignition switch is turned OFF. More than 5 hours are required to allow enough
time for the fuel to cool down to stabilize the Fuel Tank Pressure (FTP), thus making the EVAP system moni-
tor more accurate.
The electric vacuum pump creates negative pressure (vacuum) in the EVAP system and the pressure is
measured. Finally, the ECM monitors for leaks from the EVAP system, and malfunctions in both the pump
module and purge VSV, based on the EVAP pressure.
HINT:
*:If the engine coolant temperature is not below 35C 5 hours after the ignition switch is turned off, the moni-
tor check starts 2 hours later. If it is still not below 35C 7 hours after the ignition switch is turned off, the
monitor check starts 2.5 hours later.
Purge flow monitor
The purge flow monitor consists of the two monitors. The 1st monitor is always conducted every time and
the 2nd monitor is activated if necessary.

The 1st monitor
While the engine is running and the purge VSV (Vacuum Switching Valve) is ON (open), the ECM
monitors the purge flow by measuring the EVAP pressure change. If negative pressure is not
created, the ECM begins the 2nd monitor.

The 2nd monitor
The vent valve is turned ON (closed) and the EVAP pressure is then measured. If the variation
in the pressure is less than 0.5 kpa (3.75 mmHg), the ECM interprets this as the purge VSV being
stuck closed, and illuminates the MIL and sets DTC P0441 (2 trip detection logic).
Atmospheric pressure check:
In order to ensure reliable malfunction detection, the variation between the atmospheric pressures, before
and after conduction of the purge flow monitor, is measured by the ECM.