check engine light TOYOTA HIGHLANDER 2001 Service Workshop Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2001, Model line: HIGHLANDER, Model: TOYOTA HIGHLANDER 2001Pages: 2572, PDF Size: 34.8 MB
Page 2463 of 2572
05-864
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
1054 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(SLIP INDICATOR LIGHT)
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine.
(c) Select the item ºSLIP INDI LIGHTº in the ACTIVE TEST and operate the SLIP indicator light on the
hand-held tester.
ItemVehicle Condition / Test DetailsDiagnostic Note
SLIP INDI LIGHTTurns SLIP indicator light ON / OFFObserve combination me-
ter
(d) Check that ºONº and ºOFFº of the SLIP indicator light are indicated on the combination meter when
using the hand-held tester.
OK:
Turn the SLIP indicator light on or off in accordance with the hand-held tester.
NG Go to step 2
OK
REPLACE ABS & TRACTION ACTUATOR ASSY (SEE PAGE 32-37)
2 INSPECT MULTIPLEX COMMUNCATION SYSTEM (SEE PAGE 05-2040)
NG REPAIR MULTIPLEX COMMUNCATION
SYSTEM
OK
Page 2478 of 2572
05CD1-12
F45080
S27
05-784
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
974 Author: Date:
TERMINALS OF ECU
SKID CONTROL ECU
Symbols (Terminals No.)Wiring ColorTerminal DescriptionConditionSpecified Condition
BM (S27-2) - GND (Y1-1)W-L - W-BMotor relay test inputIG switch ON, pump motor running10 to 14 V
FR+ (S27-3) - FR- (S27-17)R-Y - LGFront RH wheel speed
signal inputIG switch ON, slowly turn right front
wheelAC generation
FSW+ (S27-7) - GND1
(S27-32)G-W - W-BFSW switch inputIG switch ON, brake pedal released2 to 4 V
FL+ (S27-18) - FL- (S27-4)O - PFront LH wheel speed
signal inputIG switch ON, slowly turn left front
wheelAC generation
RR+ (S27-5) - RR- (S27-19)Y - BRRear RH wheel speed
signal inputIG switch ON, slowly turn right rear
wheelAC generation
RL+ (S27-20) - RL- (S27-6)Y-G - GRear LH wheel speed sig-
nal inputIG switch ON, slowly turn left rear
wheelAC generation
TRC+ (S27-8) - TRC-
(S27-22)G-B - Y-BECM communication out-
putIG switch ONPulse generation
ENG+ (S27-9) - ENG-
(S27-23)W-L - W-GECM communication inputIG switch ONPulse generation
NEO (S27-10) - GND1
(S27-32)V - W-BEngine rpm signal inputEngine idlingPulse generation
CANH (S27-11) - CANL
(S27-25)B - WCAN communication lineIG switch OFF54 to 67 W
D/G (S27-13) - GND1
(S27-32)GR-B - W-BDiagnosis tester commu-
nication lineIG switch ON10 to 14 V
SP1 (S27-12) - GND1
(S27-32)BR-R - W-BSpeed signal outputVehicle drives at about
20 km/h (12 mph)Pulse generation
MRF (S27-14) - R+ (S27-45)G-R - B-OFail safe motor relay out-
putIG switch ON10 to 14 V
MR (S27-15) - R+ (S27-45)LG - B-OMotor relay outputIG switch ON, pump motor running10 to 14 V
+BS (S27-31) - GND1
(S27-32)B - W-BSolenoid relay power sup-
plyAlways10 to 14 V
TS (S27-24) - GND1 (S27-32)P-B - W-BSensor check inputIG switch ON10 to 14 V
STP (S27-27) - GND1GY WBSt li ht it h i t
Stop light switch ON (Brake pedal
pushed)8 to 14 VSTP (S27 27) GND1
(S27-32)G-Y - W-BStop light switch inputStop light switch OFF (Brake pedal
released)Below 1.5 V
Page 2485 of 2572
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
Page 2507 of 2572
G24767
Skid Control ECU
(harness side connector)
S27
VSCW
05-852
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
1042 Author: Date:
INSPECTION PROCEDURE
1 CHECK VSC WARNING LIGHT
WHEN USING HAND-HELD TESTER:
(a) Connect the hand-held tester to the DLC3 and start the engine.
(b) Select the item ºVSC WARN LIGHTº in the ACTIVE TEST and operate the VSC warning light on the
hand-held tester.
(c) Check that ºONº and ºOFFº of the VSC warning light are indicated on the combination meter when us-
ing the hand-held tester.
ItemVehicle Condition / Test DetailsDiagnostic Note
VSC WARN LIGHTTurns VSC warning light ON / OFFObserve combination me-
ter
OK:
Turn the VSC warning light ON or OFF in accordance with the hand-held tester.
WHEN NOT USING HAND-HELD TESTER:
(a) Turn the ignition switch off and disconnect the connector
from the skid control ECU.
(b) Ground the terminal VSCW of skid control ECU.
(c) Turn the ignition switch to the ON position.
(d) Check that the VSC warning light.
OK:
Turn the light ON or OFF in accordance with the con-
necting condition of terminal VSCW and body
ground.
NG CHECK AND REPAIR VSC WARNING LIGHT
CIRCUIT (SEE PAGE 05-1868)
OK
Page 2543 of 2572
A90849
Plastigage
A93962
5
1
3
76
2
4
8
90
Engine FrontPaint
Mark
A50671
A13392
14-48
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2541 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(f) Lay a strip of Plastigage across each journal, and install
the balanceshaft housing.
(g) Apply a light coat of engine oil on the threads and under
the heads of the balanceshaft housing bolts.
(h) Uniformly tighten the 8 bolts in the sequence shown in the
illustration.
Torque: 22 NVm (220 kgfVcm, 16 ftVlbf)
HINT:
The balanceshaft housing bolts are tightened in 2 progressive
steps.
(i) Mark the front side of each balanceshaft housing bolt
head with paint.
(j) Retighten the bolts 90 as shown in the illustration.
(k) Check that the paint marks are now at a 90 angle to the
front.
(l) Remove the balanceshaft housing, and measure the
Plastigage at its widest point.
Standard oil clearance:
0.004 to 0.031 mm (0.0002 to 0.0012 in.)
Maximum oil clearance: 0.031 mm (0.0012 in.)
(m) Completely remove the Plastigage after the inspection.
Page 2548 of 2572
EM1628
A36687
A36688
A90850
Matchmarks
Rotating Direction
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-53
2546 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
53. INSPECT NO.2 CAMSHAFT (EXHAUST)
(a) Check the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.03 mm (0.0012 in.)
If the circle runout is greater than the maximum, replace the
camshaft.
(b) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
45.983 to 46.083 mm (1.8104 to 1.8143 in.)
Minimum cam lobe height: 45.873 mm (1.8060 in.)
If the cam lobe height is less than the minimum, replace the
camshaft.
(c) Using a micrometer, measure the journal diameter.
No. 1 journal diameter:
35.971 to 35.985 mm (1.4162 to 1.4167 in.)
Other journal diameter:
22.959 to 22.975 mm (0.9039 to 0.9045 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
54. INSTALL BALANCESHAFT BEARING NO.1
(a) Install the bearings in the crankcase and balanceshaft housing.
(b) Apply a light coat of engine oil on the bearings.
55. INSTALL BALANCESHAFT NO. 1 AND NO. 2
(a) Rotate the driven gear No. 1 of balanceshaft No. 1 for the
rotating direction until it hits the stopper.
(b) Confirm that the matchmarks on driven gear No. 1 and
No. 2 are matched.
Page 2549 of 2572
Timing Marks
A13508
A93962
5
1
3
76
2
4
8
90
Engine FrontPaint
Mark
A50671
A94193
Seal Packing
Seal width: 2.5 to 3.0 mm
A
BC
D
AB
C,D
A,B: 7.5 mm (0.295 in.)
C,D: 4.0 mm (0.1575 in.)
14-54
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2547 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) Align the timing marks of the No. 1 and No. 2 balance-
shafts as shown in the illustration.
(d) Place the No. 1 and No. 2 balance shafts on the crank
case.
(e) Apply a light coat of engine oil under the heads of the bal-
ance shaft housing bolts.
(f) Uniformly tighten the 8 bolts in the sequence shown in the
illustration.
Torque: 22 NVm (224 kgfVcm, 16 ftVlbf)
HINT:
The balanceshaft housing bolts are tightened in 2 progressive
steps.
(g) Mark the front side of each balance shaft housing bolt
head with paint.
(h) Retighten the bolts by 90 as shown in the illustration.
(i) Check that the painted marks are now at a 90 angle to
the front.
56. INSTALL STIFFENING CRANKCASE ASSY
(a) Apply seal packing in a continuous bead (seal width: 2.5
to 3.0 mm (0.098 to 0.118 in.)) to the places shown in the
illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
Remove any oil from the contact surface.
Install the crankcase within 3 minutes after applying
seal packing.
Do not start the engine for at least 2 hours after instal-
ling.
Page 2551 of 2572
A36850
Mesh Part
A53039
4545A36835
A90968
Lot No.INTAKE
EXHAUST
Engine
Front
14-56
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2549 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
58. INSTALL W/HEAD TAPER SCREW PLUG NO.1
(a) Apply adhesive to the threads of the plug and install it.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equiva-
lent
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
59. I N S TA L L O I L C O N T R O L VA LV E F I LT E R F O R
CAMSHAFT TIMING
(a) Check that no foreign substance is on the mesh part of the
filter.
(b) Using a 6 mm socket hexagon wrench, install a new gas-
ket and the oil control valve filter with the screw plug.
Torque: 30 NVm (306 kgfVcm, 22 ftVlbf)
60. INSTALL CYLINDER BLOCK WATER DRAIN COCK
SUB-ASSY
(a) Install the water drain cock within the range shown in the
illustration.
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
61. INSTALL CYLINDER HEAD GASKET
(a) Place a new gasket on the cylinder block surface with the
Lot No. stamp upward.
NOTICE:
Remove any oil from contact surface.
Be careful of the installation direction.
To avoid damage to the gasket, place the cylinder
head on the gasket carefully.
62. INSTALL CYLINDER HEAD SUB-ASSY
HINT:
The cylinder head bolts are tightened in 2 progressive steps.
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) Install the 10 bolts and plate washers to the cylinder head.
NOTICE:
Do not drop the washers into the cylinder head.
Page 2552 of 2572
A941951 6 10 3 79 5 2 4 8
A00976
90
Engine
Front
Paint Mark
A53074
A13383
Straight
Pin
Key
Groove
A31033
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
14-57
2550 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) Using a 10 mm bi-hexagon wrench, uniformly tighten the
10 bolts in the sequence shown in the illustration.
Torque: 79 NVm (806 kgfVcm, 58 ftVlbf)
(d) Mark the front side of each cylinder head bolt with paint.
(e) Retighten the cylinder head bolts by 90 in the sequence
shown in the illustration.
(f) Check that the painted marks are now at a 90 angle to
the front.
63. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
64. INSTALL CAMSHAFT BEARING NO.2
(a) Install the bearing to the camshaft.
NOTICE:
Clean the contact surfaces of the bearing and the cylinder
head. the surfaces should be free of dust and oils.
65. INSTALL CAMSHAFT TIMING GEAR ASSY
(a) Put the camshaft timing gear and the camshaft together
with the straight pin and key groove.
(b) Turn the camshaft timing gear (as shown in the illustra-
tion) while pushing it lightly against the camshaft. Push
further at the position where the pin enters the groove.
CAUTION:
Be sure not to turn the camshaft timing gear to the retarded
angle side (to the right angle).
(c) Check that there is no clearance between the gear's
fringe and the camshaft.
(d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 NVm (551 kgfVcm, 40 ftVlbf)
Page 2553 of 2572
A32167
A92649
12 34 5
Bearing Cap No. 1Bearing Cap No. 3
A94196
Bearing Cap No. 2
Bearing Cap No. 3
53 1 2 4 14-58
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
2551 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(e) Check that the camshaft timing gear can move to the re-
tarded angle side (the right direction) and is locked at the
extreme retarded angle position.
HINT:
Apply a light coat of engine oil on the threads and under
the heads of the bolt.
Length of sprocket bolt excluding bolt head: 40 mm (1.57
in.)
66. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
(a) Fix the camshaft with a vise, and install the camshaft No.
2 timing gear.
Torque: 54 NVm (551 kgfVcm, 40 ftVlbf)
HINT:
Apply a light coat of engine oil on the threads and under
the heads of the bolt.
Length of sprocket bolt excluding bolt head: 25 mm (0.98
in.)
67. INSTALL CAMSHAFT BEARING NO.1
68. INSTALL CAMSHAFT (INTAKE)
(a) Examine the front marks and numbers of the 5 bearing
caps and install them. Then install the 10 bearing cap
bolts. Uniformly tighten the bolts in the sequence shown
in the illustration.
Torque:
30 NVm (306 kgfVcm, 22 ftVlbf) for bearing cap No. 1
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for bearing cap No. 3
NOTICE:
Tighten the bolts after deciding the position for the
thrust direction of the camshaft by the bearing cap
No. 1.
Install the camshaft with its timing mark of the cam-
shaft timing gear on top.
69. INSTALL NO.2 CAMSHAFT (EXHAUST)
(a) Examine the front marks and numbers of the 5 bearing
caps and install them. Then install the 10 bearing cap
bolts. Uniformly tighten the bolts in the sequence shown
in the illustration.
Torque:
30 NVm (306 kgfVcm, 22 ftVlbf) for bearing cap No. 2
9.0 NVm (92 kgfVcm, 80 in.Vlbf) for bearing cap No. 3