engine TOYOTA HIGHLANDER 2001 Service Repair Manual

2005 HIGHLANDER (EWD592U)
317
Turn Signal
Flasher
Heater Relay
Pr essure SW
Steer ing Sensor
SEAT HEATER Relay
Combination SW
Power Window
Master SW
with ECU
Remote Control
Mir ror LH Transponder Key
Computer
Body ECU
Data Link
Connector 3
Key Inter Lock
Solenoid
Remote Control
Mirror RH Door Lock Control
SW Power Window SW
Fron t RH
Door Unlock
Detection SW
Fron t RH
Wireless Door Lock
Buzzer
Br ake Pedal
Load Sensing SW4C44H11
4C6
4G9
4G8 4H7
4J6
4C3
4L9
4G10
4C5 W- B
W- B
W- B
W- B
W- B
W- B
W- B
W- BW- B
W- BW- B
W- B
W- B
B 2 I B 12
W- B
4L8
W- B
IK33
4M3
W- B
4J7 W- B
W- B4L 10 2
IN1 W- B
B 4W- B B 4 B 4
W- BW- B W- B
W- B
4N1
4L7
IC W- B
W- B(
GN D1)
(
CG)
4H5
W- B
W- B W- B
4D4
IL117
W- B W- B
4K8
W- B4D5
IE18
W- B W- B Air bag Sensor
Assembly
Front Wiper Deicer
Front Wiper Motor(
E1)
(
E2)1L9
1L1
1B9
1B8
1D14 W- B
W- B
W- B
W- B
W- B
W- B
W- B
W- B
Combination SW
Blower Motor
Control
Blower Control SW ACC Relay
IG12 W- B
W- B
W- B
IA 1E4
4M6
W- B
IH13
(
GN D)Engine
Control Module (
EOM)
1Unlock Warning SW
Door Lock Motor
Fron t RH
Door Key Lock and
Unlock SW Front RH

2005 HIGHLANDER (EWD592U)
320
I GROUND POINT
: PARTS LOCATION
CodeSee PageCodeSee PageCodeSee Page
J139 (3MZ-FE)J439 (3MZ-FE)J1844J141 (2AZ-FE)J441 (2AZ-FE)J1944
J239 (3MZ-FE)J743J21A46 (w/ Power Seat)J241 (2AZ-FE)J1244J22B46 (w/ Power Seat)
J339 (3MZ-FE)J1344J23A46 (w/ Power Seat)J341 (2AZ-FE)J1444J24B46 (w/ Power Seat)
: RELAY BLOCKS
CodeSee PageRelay Blocks (Relay Block Location)
222Engine Room R/B (Engine Compartment Left)
323Engine Room R/B No.3 (Engine Compartment Rear Left)
: JUNCTION BLOCK AND WIRE HARNESS CONNECTOR
CodeSee PageJunction Block and Wire Harness (Connector Location)
1B29Engine Room Main Wire and Instrument Panel J/B (Lower Finish Panel)
1D
1E29Cowl Wire and Instrument Panel J/B (Lower Finish Panel)
1L
()
2A
2F27Engine Room Main Wire and Engine Room J/B (Engine Compartment Left)
2G
gg(g)
3A
3B
3D30
3E
3FInstrument Panel Wire and Center J/B (Behind the Instrument Panel Center)3GInstrument Panel Wire and Center J/B (Behind the Instrument Panel Center)
3H
3I31
3J
3K
4C
4D334G33
4H
4JCowl Wire and Passenger Side J/B (Right Side of Grove Box)
4K
g(g )
4L32
4M
4N

2005 HIGHLANDER (EWD592U)
321
: CONNECTOR JOINING WIRE HARNESS AND WIRE HARNESS
CodeSee PageJoining Wire Harness and Wire Harness (Connector Location)
IB152Front Door LH Wire and Cowl Wire (Left Kick Panel)
IE152Roof Wire and Cowl Wire (Near the Bottom of Left Front Pillar)
IG152Instrument Panel Wire and Cowl Wire (Upper Portion of Right Instrument Panel Brace)
IH154Cowl Wire and A/C Sub No.2 Wire (Upper Portion of Right Instrument Panel Brace)
II154Instrument Panel Wire and A/C Sub No.1 Wire (Upper Portion of Right Instrument Panel Brace)
IK354Engine Room Main Wire and Cowl Wire (Right Cowl Side Panel)
IL154Instrument Panel Wire and Cowl Wire (Upper Side of Passenger Side J/B)
IM154Engine Wire and Cowl Wire (Right Kick Panel)
IN154Front Door RH Wire and Cowl Wire (Right Kick Panel)
IR254Instrument Panel Wire and Floor Wire (Under the Shift Lever)
BB156Rear Door No.1 LH Wire and Floor No.2 Wire (Left Center Pillar)
BC156Rear Door No.1 RH Wire and Floor Wire (Right Center Pillar)
BG156Back Door No.1 Wire and Floor No.2 Wire (Rear Left of the Roof)
BH156Floor No.2 Wire and Floor Wire (Near the Rear Side Marker Light RH)
BJ156Floor Wire and Floor No.4 Wire (Right Side of Rear Floor Crossmember)
BL158Floor Wire and Front Seat RH Wire (Under the Front Passenger's Seat)BM158Floor Wire and Front Seat RH Wire (Under the Front Passenger's Seat)
: GROUND POINTS
CodeSee PageGround Points Location
EA48 (3MZ-FE)EA50 (2AZ-FE)Right Front Fender Apron
EB48 (3MZ-FE)Right Front Fender Apron
EB50 (2AZ-FE)
EC48 (3MZ-FE)Left Side of Cylinder Head
ED48 (3MZ-FE)Rear Side of Cylinder Head
EE50 (2AZ-FE)Intake Side of Cylinder Block
EF50 (2AZ-FE)Left Side of Cylinder Block
EG48 (3MZ-FE)EG50 (2AZ-FE)Under the Left Headlight
EH48 (3MZ-FE)Under the Left Headlight
EH50 (2AZ-FE)
IA52Left Cowl Side Panel
IB52Right Instrument Panel Brace
IC52Right Cowl Side Panel
BA56Left Center Pillar
BB56Right Center Pillar
BC56Left Side of Rear Cross Member
BE56Left Side of Back Door
BF56Near the Rear Side Marker Light RH
: SPLICE POINTS
CodeSee PageWire Harness with Splice PointsCodeSee PageWire Harness with Splice Points
E648 (3MZ-FE)Engine WireI654Engine Wire
E950 (2AZ-FE)Engine WireB156Roof Wire
E1148 (3MZ-FE)B256Front Door LH WireE1150 (2AZ-FE)Engine Room Main WireB456Front Door RH Wire
E1248 (3MZ-FE)Engine Room Main WireB956Floor No.2 WireE1250 (2AZ-FE)

2005 HIGHLANDER (EWD592U)
5
B
[A]: System Title
[B]: Indicates a Relay Block. No shading is used and
only the Relay Block No. is shown to distinguish it
from the J/B
Example: Indicates Relay Block No.1
[C]: ( ) is used to indicate different wiring and
connector, etc. when the vehicle model, engine
type, or specification is different.
[D]: Indicates related system.
[E]: Indicates the wiring harness and wiring harness
connector. The wiring harness with male terminal is
shown with arrows (
).
Outside numerals are pin numbers.
Female Male ( )
The first letter of the code for each wiring harness
and wiring harness connector(s) indicates the
component's location, e.g, ºEº for the Engine
Compartment, ºIº for the Instrument Panel and
Surrounding area, and ºBº for the Body and
Surrounding area.
When more than one code has the first and second
letters in common, followed by numbers (e.g, IH1,
IH2), this indicates the same type of wiring harness
and wiring harness connector.
[F]: Represents a part (all parts are shown in sky blue).
The code is the same as the code used in parts
position.
[G]: Junction Block (The number in the circle is the J/B
No. and the connector code is shown beside it).
Junction Blocks are shaded to clearly separate
them from other parts.
3C indicates that
it is inside
Junction Block
No.3
Example:
[H]: Indicates the wiring color.
Wire colors are indicated by an alphabetical code.
B = Black W = White BR = Brown
L = Blue V = Violet SB = Sky Blue
R = Red G = Green LG = Light Green
P = Pink Y = Yellow GR = Gray
O = Orange
The first letter indicates the basic wire color and the
second letter indicates the color of the stripe.
Example: L - Y
L
(Blue)Y
(Yellow)
[I]: Indicates a wiring Splice Point (Codes are ºEº for the
Engine Room, ºIº for the Instrument Panel, and ºBº
for the Body).
The Location of splice Point I 5 is indicated by the
shaded section.
[J]: Indicates a shielded cable.
[K]: Indicates the pin number of the connector.
The numbering system is different for female and
male connectors.
Example:
Numbered in order
from upper left to
lower rightNumbered in order
from upper right to
lower left
Female
Male
[L]: Indicates a ground point.
The first letter of the code for each ground point(s)
indicates the component's location, e.g, ºEº for the
Engine Compartment, ºIº for the Instrument Panel
and Surrounding area, and ºBº for the Body and
Surrounding area.
[M]: Page No.

2005 HIGHLANDER (EWD592U)
9
B
The ºCurrent Flow Chartº section, describes which parts each power source (fuses, fusible links, and circuit breakers)
transmits current to. In the Power Source circuit diagram, the conditions when battery power is supplied to each system
are explained. Since all System Circuit diagrams start from the power source, the power source system must be fully
understood.
ACC
S 26
652
22
Battery30A AM2
StarterShort Pin
100A ALT Fusible Link Block
60A ABS10A ECU-B
7.5A DOME
15A EFI
10A HAZARD
20A RADIO NO.1
10A HORN
20A
10AFusePage
214
230
11 2
122 194
187
180
166
210 ABS
Cigarette Lighter
Combination Meter
Key Reminder and Seat Belt Warning
Light Auto Turn Off
Theft Deterrent and Door Lock ControlABS and Traction Control
Cruise Control
Electronically Controlled Transmission
Multiplex Communication System STOPSystem
DOMEHeadlight
Interior Light
3 EA2 1 EA1E 6
E 7
E 7
2
2
2
2 2
2 2
2 INJECTION Relay
STARTER Relay B
B
B B-O
1
1 2
23
4
3
4W-B W-B
B-W
B-W E 7
E 7B
BW1.25B FL MAIN
50A MAIN
7.5A AM2
15A HAZ-RADIO 2
22
2
2W
WEB1
EB17
6
W-RI 2 I 2 I 2
WW
W W W
1 1
1 140A DOOR LOCK CB
7.5A DOME 1W-L
R 1
1
2
431
1 1
1
111 G
G
W-R 15A TAIL
20A DEFOG
B-Y 84
32Ignition SW I 8
B-Y
11P-L Battery
15A RAD CIG2
TAIL
Relay
Power Source J POWER SOURCE (Current Flow Chart)
Engine Room R/B (See Page 20)
2
W W
B B B B B
W-R
WW W
G-WAM2
AM1 IG2
IG1W
W
The chart below shows the route by which current flows from the battery to each electrical source
(Fusible Link, Circuit Breaker, Fuse, etc.) and other parts.
*The system shown here is an EXAMPLE ONLY. It is different to the actual circuit shown in the SYSTEM CIRCUITS SECTION.

051ZF-14
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-5
195 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
HOW TO PROCEED WITH TROUBLESHOOTING
The hand-held tester is used in steps 3, 4, 5, 7 and 10.
1 VEHICLE BROUGHT TO WORKSHOP
NEXT
2 CUSTOMER PROBLEM ANALYSIS (See page 05-8)
NEXT
3 CONNECT HAND-HELD TESTER TO DLC3
HINT:
If the display indicates a communication fault in the tool, inspect the DLC3.
NEXT
4 CHECK DTC AND FREEZE FRAME DATA (See page 05-38)
HINT:
Record or print DTC and freeze frame data, if needed.
NEXT
5 CLEAR DTC AND FREEZE FRAME DATA (See page 05-38)
NEXT
6 VISUAL INSPECTION
NEXT
7 SETTING CHECK (TEST) MODE DIAGNOSIS (See page 05-40)
NEXT
8 PROBLEM SYMPTOM CONFIRMATION
HINT:
If the engine does not start, perform steps 10 and 12 first.
Malfunction does not occurA
Malfunction occursB
B Go to step 10
A

141P0-02
A87787
CORRECTINCORRECT
A80020
Hand-held Tester
DLC3
A82779
7 6 5 34 2 18
9 10111213141516DLC3
CG
TC
- ENGINE MECHANICALENGINE (2AZ-FE)
14-1
2494 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
ENGINE (2AZ-FE)
INSPECTION
1. INSPECT ENGINE COOLANT (See page 16-6)
2. INSPECT ENGINE OIL
3. INSPECT BATTERY
4. INSPECT AIR CLEANER FILTER ELEMENT SUB-ASSY
5. INSPECT SPARK PLUG (See page 18-3)
6. INSPECT V-RIBBED BELT
HINT:

After installing the drive belt, check that it fits properly in
the ribbed grooves. Check with your hand to confirm that
the belt has not slipped out of the groove on the bottom
of the crank pulley.

ºNew beltº is a belt which has been used less than 5 min-
utes on a running engine.

ºUsed beltº is a belt which has been used on a running en-
gine for 5 minutes or more.

After installing a new belt, run the engine for approximate-
ly 5 minutes and then recheck the tension.
7. INSPECT IGNITION TIMING
(a) Warm up the engine.
(b) When using the hand-held tester:
Check the ignition timing.
(1) Connect the hand-held tester to the DLC3.
(2) Enter DATA LIST MODE on the hand-held tester.
Ignition timing: 8 to 12 BTDC @ idle
HINT:
Please refer to the hand-held tester operator's manual for help
on selecting the DATA LIST.
(c) When not using the hand-held tester:
Check the ignition timing.
(1) Using SST, connect terminals 13 (TC) and 4 (CG)
of the DLC3.
SST 09843-18040
NOTICE:

Confirm the terminal numbers before connecting
them. Connection with a wrong terminal can damage
the engine.

Turn off all electrical systems before connecting the
terminals.

Perform this inspection after the cooling fan motor is
turned off.

A52004
A80020
Hand-held Tester
DLC3
A82779
7 6 5 34 2 18
9 10111213141516DLC3
TA C
14-2
- ENGINE MECHANICALENGINE (2AZ-FE)
2495 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(2) Remove the cylinder head cover No. 2.
(3) Pull out the wire harness as shown in the illustration.
Connect the clip of the timing light to the engine.
NOTICE:

Use a timing light which can detect the first signal.

After checking, be sure to tape the wire harness.
(4) Check the ignition timing at idle.
Ignition timing: 8 to 12 BTDC @ idle
NOTICE:
When checking the ignition timing, the transmission
should be in the neutral position.
HINT:
After engine rpm is kept at 1,000 to 1,300 rpm for 5 seconds,
check that it returns to idle speed.
(5) Remove the SST from the DLC3.
SST 09843-18040
(6) Check the ignition timing at idle.
Ignition timing: 5 to 15 BTDC @ idle
(7) Confirm that ignition timing moves to the advanced
angle side when the engine rpm is increased.
(8) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up the engine.
(b) When using the hand-held tester:
Check the idle speed.
(1) Connect the hand-held tester to the DLC3.
HINT:
Please refer to the hand-held tester operator's manual for fur-
ther details.
(2) Enter DATA LIST MODE on the hand-held tester.
Idle speed: 610 to 710 rpm
NOTICE:

When checking the idle speed, the transmission
should be in the neutral position.

Check idle speed with the cooling fan off.

Switch off all accessories and air conditioning before
connecting the hand-held tester.
(c) When not using the hand-held tester:
Check the idle speed.
(1) Using SST, connect tachometer tester probe to ter-
minal 9 (TAC) of the DLC3.
(2) Check the idle speed.
Idle speed: 610 to 710 rpm
SST 09843-18030

A01037
- ENGINE MECHANICALENGINE (2AZ-FE)
14-3
2496 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the ignition coils.
(d) Remove the spark plugs.
(e) Check the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug
hole.
(2) Fully open the throttle.
(3) While cranking the engine, measure the compres-
sion pressure.
Compression pressure:
1,360 kPa (13.9 kgf/cm
2, 198 psi)
Minimum pressure: 0.98 MPa (10 kgf/cm
2, 142 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 14 psi)
NOTICE:

Always use a fully charged battery to obtain engine
speed of 250 rpm or more.

Check other cylinder's compression pressure in the
same way.

This measurement must be done as quickly as pos-
sible.
(4) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through the
spark plug hole and inspect again.
HINT:

If adding oil increases the compression, the piston rings
and/or cylinder bore may be worn or damaged.

If pressure stays low, a valve may be stuck or seated im-
properly, or there may be leakage in the gasket.
10. INSPECT CO/HC
(a) Start the engine.
(b) Rev the engine at 2,500 rpm for approximately 180 seconds.
(c) Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.
(d) Immediately check CO/HC concentration at idle and/or 2,500 rpm.
HINT:

Complete the measuring within 3 minutes.

Check regulations and restrictions in your area when performing 2 mode CO/HC concentration testing
(engine check at both idle speed and at 2,500 rpm).
(e) If the CO/HC concentration does not comply with regulations, troubleshoot in the order given below.
(1) Check A/F sensor operation (see page 12-3).
(2) See the table below for possible causes, and then inspect and repair.

14-4
- ENGINE MECHANICALENGINE (2AZ-FE)
2497 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)CO
HCProblemsCauses
NormalHighRough idle
1. Faulty ignitions:

Incorrect timing

Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaky intake and exhaust valves
4. Leaky cylinders
LowHighRough idle
(fluctuating HC reading)
1. Vacuum leaks:

PCV hoses

Intake manifold

Throttle body

Brake booster line
2. Lean mixture causing misfire
HighHighRough idle
(black smoke from exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI system:

Faulty pressure regulator

Defective ECT

Defective MAF meter

Faulty ECM

Faulty injectors

Faulty throttle position sensor