engine TOYOTA HIGHLANDER 2001 Service Repair Manual

05-346
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
536 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
Monitor Confirmation
HINT:
After a repair, check Monitor Status by performing the Key-Off Monitor Confirmation and Purge Flow Monitor
Confirmation described below.
1. KEY-OFF MONITOR CONFIRMATION
(a) Preconditions
The monitor will not run unless:

The vehicle has been driven for 10 minutes or more (in a city area or on a free way)

The fuel tank is less than 90% full

The altitude is less than 8,000 ft (2,400 m)

The Engine Coolant Temperature (ECT) is between 4.4C and 35C (40F and 95F)

The Intake Air Temperature (IAT) is between 4.4C and 35C (40F and 95F)

The vehicle remains stationary (the vehicle speed is 0 mph [0 km/h])
(b) Monitor Conditions
(1) Allow the engine to idle for at least 5 minutes.
(2) Turn the ignition switch OFF and wait for 6 hours (8 or 10.5 hours).
HINT:
Do not start the engine until checking MONITOR STATUS. If the engine is started, the steps described above
must be repeated.
(c) Monitor Status
(1) Connect a hand-held tester to the DLC3.
(2) Turn the ignition switch ON and turn the tester ON.
(3) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR
STATUS.
(4) Check the Monitor Status displayed on the tester.
HINT:
If INCMP is displayed, the monitor is not completed. Make sure that the preconditions have been met, and
perform the Monitor Conditions again.
2. PURGE FLOW MONITOR CONFIRMATION (P0441)
HINT:
Perform this monitor confirmation after the Key-Off Monitor Confirmation shows COMPL (complete).
(a) Preconditions
The monitor will not run unless:

The vehicle has been driven for 10 minutes or more (in a city area or on a free way)

The ECT is between 4.4C and 35C (40F and 95F)

The IAT is between 4.4C and 35C (40F and 95F)
(b) Monitor Conditions
(1) Release the pressure from the fuel tank by removing and reinstalling the fuel tank cap.
(2) Warm the engine up until the ECT reaches more than 75C (167F).
(3) Increase the engine speed to 3,000 rpm once.
(4) Allow the engine to idle and turn A/C ON for 1 minute.
(c) Monitor Status
(1) Turn the ignition switch OFF (where ON or the engine is running).
(2) Connect a hand-held tester to the DLC3.
(3) Turn the ignition switch to ON and turn the tester ON.
(4) On the tester, select the following menu items: DIAGNOSIS / ENHANCED OBD II / MONITOR
STATUS.
(5) Check the Monitor Status displayed on the tester.

05ESR-05
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232 Author
: Date
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
FAIL-SAFE CHART
If any of the following codes are recorded, the ECM enters fail-safe mode.
DTC No.Fail-Safe OperationFail-Safe Deactivation Conditions
P0031
P0032
P0037
P0038
Turn off heaterIgnition switch OFF
P0100
P0102
P0103Ignition timing is calculated from engine speed and throttle
angleºPassº condition detected
P0110
P0112
P0113
Intake air temperature is fixed at 20°C (68°F)ºPassº condition detected
P0115
P0116
P0117
P0118
Engine coolant temperature is fixed at 80°C (176°F)ºPassº condition detected
P0120
P0121
P0122
P0123
P0220
P0222
P0223
P0604
P0606
P0607
P0657
P2102
P2103
P2111
P2112
P2118
P2119
P2135
If Electronic Throttle Control System (ETCS) has malfunc-
tion, ECM cuts off current to throttle control motor. Throttle
control valve returns to predetermined opening angle
(approximately 16
) by force of return spring. ECM then
adjusts engine output by controlling fuel injection (intermit-
tent fuel-cut) and ignition timing in accordance with acceler-
ator pedal opening angle to enable vehicle to continue at
minimal speed.
If accelerator pedal is depressed firmly and slowly, vehicle
can be driven slowly. If accelerator pedal is depressed
quickly, vehicle may speed up and slow down erratically.
ºPassº condition is detected and then ignition switch is turned
OFF, fail-safe operation will stop and system will return to
normal condition
P0325
P0327
P0328
Maximum timing retardationIgnition switch OFF
P0351
P0352
P0353
P0354
Fuel is cutºPassº condition detected
P2120
P2121
P2122
P2123
P2125
P2127
P2128
P2138Accelerator pedal position sensor has two (main and sub)
sensor circuits. If malfunction occurs in either of sensor
circuits, ECM detects abnormal signal voltage difference
between two sensor circuits and switches to limp mode. In
limp mode, remaining circuit is used to calculate accelerator
pedal opening to allow vehicle to continue driving.
If both circuits malfunction, ECM regards opening angle of
accelerator pedal to be fully closed. In this case, throttle
valve will remain closed as if engine is idling.
ºPassº condition is detected and then ignition switch is turned
OFF, fail-safe operation will stop and system will return to
normal condition

A90307
AM2
Main
StarterCircuit Opening Relay
PNP Switch ST1EFI Relay
ALT
Battery AM1ECM
NE STAMREL
IGSW EFI NO. 1
Ignition Switch
AM1
AM2Fuel Pump
ST2IG2IGN
(NE Signal) (STA Signal)FC
Tr
STARTER
STARTER
Relay
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-349
539 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
FUEL PUMP CONTROL CIRCUIT
CIRCUIT DESCRIPTION
When the engine is cranked, current flows from the ignition switch terminal ST1 to the starter relay coil (Mark-
ing: STARTER), and current flows to terminal STA of the ECM (STA signal).
When the STA signal and NE signal are input to the ECM, Tr is turned ON, current flows to coil of the circuit
opening relay, (Marking) the relay switches on, power is supplied to the fuel pump and the fuel pump oper-
ates.
While the NE signal is generated and the engine is running, the ECM keeps Tr ON (Circuit Opening relay
ON) and the fuel pump also keeps operating.
05EW0-05

A90308
IG2I15
Ignition Switch
FC MRELECM
Y8
E5
6
7
4 Engine
Room J/B
AM2
FL
Main
Battery
EHW-B IGN
IC1
2F
E510 IA2 32 51
1
3
5
2
3 10
1AM2
EFI
NO. 1EFI
Relay
W
F12
Fuel Pump
BCBR
8 F7
FL Block AssyCircuit
Opening
Relay B
L L-Y
W
W-B
J2
J/C A Y
1 11 1
52B
12I82B
1IK3
2
IC213
B WWW
P-L GRInstrument Panel J/B AssyPassenger Side J/B
R/B No.1 4M4
4F1
1G6
1C1
54 05-350
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
540 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
WIRING DIAGRAM

I30515
+B A1012
1K
IC3Instrument Panel J/B
W 2
1ECU-B Engine Room J/B
FL MAIN
BatteryA/C Amplifier Assy
10
1G BR W-L5 4
2A D.C.C
2I W
1 3
WF7
Fusible
Link
Block
- DIAGNOSTICSAIR CONDITIONING SYSTEM
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
BACK-UP POWER SOURCE CIRCUIT
CIRCUIT DESCRIPTION
This is the back-up power source for the A/C amplifier assy. Power is supplied even when the ignition switch
is off and is used for diagnostic trouble code memory, etc.
WIRING DIAGRAM
05IU3-01

I30331+B (+)
A/C Amplifier Connector
Wire Harness View:
A10
I38763
A10
GND+B
A/C Amplifier Connector Wire Harness View:
05-1 174
- DIAGNOSTICSAIR CONDITIONING SYSTEM
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
INSPECTION PROCEDURE
1 CHECK FUSE(ECU-B FUSE)
(a) Remove the ECU-B fuse from the engine room J/B.
(b) Check that the continuity exits of ECU-B fuse.
NG REPLACE FUSE
OK
2 INSPECT AIRCONDITIONER AMPLIFIER ASSY(+B)
(a) Remove the A/C amplifier assy with connectors still con-
nected.
(b) Measure the voltage according to the value(s) in the table
below.
Standard:
Tester connectionConditionSpecified condition
A10-12 (+B) -
Body groundAlways10 to 14 V
OK PROCEED TO NEXT CIRCUIT INSPECTION
SHOWN IN PROBLEM SYMPTOMS TABLE (SEE
PAGE 05-1 129)
NG
3 CHECK HARNESS AND CONNECTOR(A/C AMPLIFIER ASSY - BATTERY)
(a) Remove the A/C amplifier assy and disconnect the con-
nector.
(b) Measure the voltage according to the value(s) in the table
below.
Standard:
Tester connectionConditionSpecified condition
A10-12 (+B) -
A10-1 1 (GND)Always10 to 14 V
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK
REPLACE AIRCONDITIONER AMPLIFIER ASSY

I30520
ECM
ACMG 2
E6 O
IK3 Magnetic Clutch Relay
9 18 From Fan No. 3
Relay
Y-G
Y-G
EB2
B-Y
3 2
3 8
A2
A/C Magnetic
Clutch and
Lock Sensor 3 2 1
52C
2E 2A B-R
IK27Engine Room J/B
Y From
Battery 05-1 190
- DIAGNOSTICSAIR CONDITIONING SYSTEM
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
COMPRESSOR CIRCUIT
CIRCUIT DESCRIPTION
The ECM and A/C amplifier communicate via BEAN.
The A/C amplifier assy outputs the magnetic clutch ON signal to the ECM.
Receiving this signal, the ECM sends a signal through terminal ACMG and switches the magnetic clutch
relay ON, thus turning on the magnetic clutch.
WIRING DIAGRAM
05IU8-01

- DIAGNOSTICSAIR CONDITIONING SYSTEM
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
INSPECTION PROCEDURE
1 READ VALUE OF HAND-HELD TESTER
(a) Connect the hand-held tester to the DLC3.
(b) Turn the ignition switch ON and push the hand-held tester main switch ON.
(c) Select the items below in the DATA LIST, and read the displays on the hand-held tester.
ENGINE AND ECT / ALL:
ItemMeasurement Item/Display
(Range)Normal ConditionDiagnostic Note
A/C SIGA/C signal/ ON or OFFA/C ON: ON-
A/C MAG CLUTCHA/C magnet clutch/ ON or OFFA/C magnet clutch ON: ON-
NG INSPECT MULTIPLEX COMMUNICATION
CIRCUIT
OK
2 PERFORM ACTIVE TEST USING HAND-HELD TESTER
(a) Connect the hand-held tester to the DLC3.
(b) Turn the ignition switch ON and push the hand-held tester main switch ON.
(c) Select the item below in the ACTIVE TEST, and then check that the relay operates.
ENGINE AND ECT / ALL:
ItemTest Details/Display (Range)Diagnostic Note
A/C MAG CLUTCHMagnetic clutch relay / OFF, ONOperating sound can be heard
NG Go to step 3
OK
PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE (SEE PAGE
05-1 129)

Z18060
5
13
2
23
15
le32E05280
Magnet Clutch Assy Connector
From View:
A2
I36159
ECM Connector Wire Harness View:
E6
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
3 INSPECT MAGNET-CLUTCH RELAY
(a) Remove the relay (magnet clutch relay) from the engine
room R/B.
(b) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester connectionConditionSpecified condition
3 - 5Always10 kW or higher
3 - 5When battery voltage ap-
plied to terminals 1 and 2Below 1 W
NG REPLACE MAGNET-CLUTCH RELAY
OK
4 INSPECT MAGNET CLUTCH ASSY
(a) Disconnect the connector from the magnet clutch assy.
(b) Connect the positive (+) lead from the battery to terminal
3 and negative (-) lead to body ground, then check that
the magnet clutch assy is engaged.
NG REPLACE MAGNET CLUTCH ASSY
OK
5 INSPECT ECM
(a) Remove the ECM and disconnect the connector.
(b) Measure the voltage according to the value(s) in the table
below.
Standard:
Tester connectionConditionSpecified condition
E6-2 (ACMG) - Body
groundIgnition switch ON10 to 14 V
NG REPAIR OR REPLACE HARNESS AND
CONNECTOR
OK

E74086
D6
Door Courtesy Lamp Front RHBody ECU
D5
Door Courtesy Lamp Front LH
I14
Ignition Key Cylinder Illumination
T7 Ignition Key Cylinder Illumination
(Transponder Key Amplifier)Passenger Side J/B
I16
Interior Lamp
O5
Overhead J/B
Engine Room J/B
Instrument Panel J/B
F7
FL Block
*1: w/ Engine Immobilizer System
*2: w/o Engine Immobilizer System BR G O10
IN2 3
IN112
B12 PCYL
DCYL 19
B11
11
B12
ILE Y
L 10
IB2 O
1
2 12
3
IB1G V Y8
IL1
Y (*2)
G (*2)
21
Y (*1)
26G (*1)5
4J2
4FBR
1
4H
5
4D
13
12
4D7
4L
1
4N
6
4HW-B
W-B
V
12
IK3 R 3
2A DOME
D.C.C 1
2IG
W-B
B R
R5
IE1
8
IE1
1
IE1 1DOOR
OFF
ON2
3
WW
W
+B1
CTY 712
6
1KP FR DOOR
12
1DD FR DOOR
1
1AW
B3
2ALT
1
Battery
FL MAINIC 4D R
W-B
W
- DIAGNOSTICSLIGHTING SYSTEM
05-1607
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: Date
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
WIRING DIAGRAM