engine TOYOTA HIGHLANDER 2001 Service Repair Manual

'05 HIGHLANDER_U (L/O 0409)
iv
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
In order to be effective, the SRS airbags must deploy with
tremendous speed. The rapid deployment of the SRS air-
bags makes the SRS airbags themselves potential sources
of serious injury if an occupant is too close to an airbag,
or if an object or some part of his or her body has been
placed between the occupant and the airbag at the time of
deployment. This is just one example of how the instruc-
tions in Section 1- 3 of this Owner 's Manual will help en-
sure proper use of the occupant restraint systems, and
increase the safety they can provide to you and your fami-
ly in the event of an accident.
Toyota recommends you to read the provisions in Section
1- 3 carefully and refer to them as needed during your time
of ownership of this vehicle.Event data recorder
Your vehicle has computers that monitor and control cer-
tain aspects of your vehicle. These computers assist in
driving and maintaining optimal vehicle performance. Be-
sides storing data useful for troubleshooting, there is a
system to record data in a crash or a near car crash
event. This is called an Event Data Recorder (EDR).
The SRS airbag sensor assembly contains the EDR. In a
crash or a near car crash event, this device records some
or all of the following information:

Engine speed

Whether the brake pedal was applied or not

Vehicle speed

To what extent the accelerator pedal was depressed

Position of the transmission selector lever

Whether the driver and front passenger wore the seat
belts or not

Driver 's seat position

Front passenger 's occupant classification

'05 HIGHLANDER_U (L/O 0409)
vi
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
Your responsibility for
maintenance
It is the owner 's responsibility to make sure that the
specified maintenance is performed. Section 6 gives
details of these maintenance requirements. Also included
in Section 6 is general maintenance. For scheduled
maintenance information, please refer to the Scheduled
Maintenance Guideº or Owner 's Manual Supplementº.
Important health and safety
information about your Toyota
CAUTION

WARNING: Engine exhaust, some of its constitu-
ents, and a wide variety of automobile compo-
nents contain or emit chemicals known to the
State of California to cause cancer and birth de-
fects and other reproductive harm. In addition,
oils, fuels and fluids contained in vehicles as
well as waste produced by component wear con-
tain or emit chemicals known to the State of
California to cause cancer and birth defects or
other reproductive harm.

Battery posts, terminals and related accessories
contain lead and lead compounds. Wash your
hands after handling. Used engine oil contains
chemicals that have caused cancer in laboratory
animals. Always protect your skin by washing
thoroughly with soap and water.

'05 HIGHLANDER_U (L/O 0409)
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2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
On- pavement and off- road
driving tips
This vehicle belongs to the utility vehicle class. Utility ve-
hicles have a significantly higher rollover rate than other
types of vehicles. This vehicle will handle and maneuver
differently from an ordinary passenger car because it is
designed for off- road use also. In addition, this vehicle
has a higher ground clearance and center of gravity than
that of an ordinary passenger car. This vehicle design fea-
ture causes this type of vehicle to be more likely to rol-
lover. Failure to operate this vehicle correctly may result in
loss of control, accidents or vehicle rollover causing death
or serious injury. Be sure to read Off- road vehicle precau-
tionsº on page 290 in Section 2 and Off- road driving pre-
cautionsº on page 320 in Section 3.
Leak detection pump
(2AZ- FE engine)
This pump performs fuel evaporation leakage check. This
check is done approximately five hours after the engine is
turned off. So you may hear sound coming from under-
neath the luggage compartment for several minutes. It
does not indicate a malfunction.

100FT-04
321 4 5
-20
020 40 60
80100 0.1 0.2 0.3 0.51 235 1020 30
Temperature
C (
F)
Resistance kW
(-4) (32) (68) (140)(104) (212)(176)
Air
E2
THAVG
E2G+B
A93068
12
Valve
A50377
- ENGINE CONTROL SYSTEMSFI SYSTEM (3MZ-FE)
10-13
2371 Author
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INSPECTION
1. INSPECT MASS AIR FLOW METER
(a) Check the output voltage.
(1) Apply battery voltage across terminals 1 (+B) and 2
(E2G).
(2) Connect the positive (+) tester probe to terminal
VG, and negative (-) tester probe to terminal E2G.
(3) Blow air into the Mass Air Flow (MAF) meter, and
check that the voltage fluctuates.
(b) Measure the resistance between terminals 4 (THA) and
5 (E2).
Standard:
ConditionSpecified Condition
-20
C (-4
F)13.6 to 18.4 kW
20
C (68
F)2.21 to 2.69 kW
60
C (140
F)0.493 to 0.667 kW
If the result is not as specified, replace the MAF meter.
2. INSPECT CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Measure the resistance between the terminals.
Standard: 6.9 to 7.9 W at 20
C (68
F)
If the result is not as specified, replace the OCV assy.
(b) Connect the battery's positive (+) lead to terminal 1 and
negative (-) lead to terminal 2, and check the movement
of the valve.
NOTICE:
Confirm that the valve moves freely and does not become
stuck in any position.
If necessary, replace the OCV assy.
HINT:
If the valve cannot return properly because of foreign matter, a
small pressure leak in the advanced direction may occur and a
DTC will be output.

1 2 3 4 5 6
A75258
M- M+ VTA VC VTA2 E2
Temperature
C (
F)
Resistance kW
30
20
10
5
2
1
0.5
0.3
0.2
0.13
-20 0 20 40 60 80 100
(-4)(32) (68) (140)(104) (212)
(176)
A91320
A65174
10-14
- ENGINE CONTROL SYSTEMSFI SYSTEM (3MZ-FE)
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3. INSPECT ACCELERATOR PEDAL ROD ASSY
(a) Check the acceletor pedal position sensor (see page 05-469).
4. INSPECT THROTTLE BODY ASSY
(a) Check the throttle position sensor (see page 05-469).
(b) Check the throttle control motor.
(1) Measure the resistance between terminals 2 (M+)
and 1 (M-).
Resistance: 0.3 to 100 W at 20
C (68
F).
If the result is not as specified, replace the throttle body assy.
5. INSPECT ENGINE COOLANT TEMPERATURE
SENSOR
(a) Measure the resistance between each terminal.
Standard:
ConditionSpecified Condition
20
C (68
F)2.32 to 2.59 kW
80
C (176
F)0.310 to 0.326 kW
If the result is not as specified, replace the sensor.
NOTICE:
If checking the ECT sensor in the water, keep the terminals
dry. After the check, wipe the sensor dry.
6. INSPECT KNOCK SENSOR
(a) Measure the resistance between the terminals.
Resistance: 120 to 280 kW at 20
C (68
F)
If the result is not as specified, replace the sensor.

A93067
5 2
1
3
1
32
5
A93067
5 2
1
3
1
32
5
- ENGINE CONTROL SYSTEMSFI SYSTEM (3MZ-FE)
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7. INSPECT RELAY (Marking: EFI, A/F)
(a) Remove the EFI relay from the engine room J/B.
(b) Remove the A/F relay from the engine room R/B No. 2.
(c) Measure the resistance of the relay.
Standard:
Tester ConnectionSpecified Condition
3 - 510 kW or higher
3 - 5Below 1W
(when battery voltage is applied to terminals 1 and 2)
If the result is not as specified, replace the relay.
8. INSPECT CIRCUIT OPENING RELAY
(a) Remove the circuit opening relay from the R/B sub-assy.
(b) Measure the resistance of the relay.
Standard:
Tester ConnectionSpecified Condition
3 - 510 kW or higher
3 - 5Below 1W
(when battery voltage is applied to terminals 1 and 2)
If the result is not as specified, replace the relay.

01-42
- INTRODUCTIONTERMS
42 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)Abbreviations Meaning
DEFDefogger
DFLDeflector
DIFF.Differential
DIFF. LOCKDifferential Lock
D/INJDirect Injection
DLCData Link Connector
DLIDistributorless Ignition
DOHCDouble Overhead Camshaft
DPDash Pot
DSDead Soak
DSPDigital Signal Processor
DTCDiagnostic Trouble Code
DVDDigital Versatile Disc
EBDElectric Brake Force Distribution
ECAMEngine Control And Measurement System
ECDElectronic Controlled Diesel
ECDYEddy Current Dynamometer
ECTElectronic Control Transmission
ECUElectronic Control Unit
EDElectro-Deposited Coating
EDUElectronic Driving Unit
EDICElectric Diesel Injection Control
EFIElectronic Fuel Injection
E/GEngine
EGRExhaust Gas Recirculation
EGR-VMEGR-Vacuum Modulator
ELREmergency Locking Retractor
EMPSElectric Motor Power Steering
ENGEngine
ESAElectronic Spark Advance
ETCS-iElectronic Throttle Control System-intelligent
EVAPEvaporative Emission Control
EVPEvaporator
E-VR VElectric Vacuum Regulating Valve
EXExhaust
FEFuel Economy
FFFront-Engine Front-Wheel-Drive
F/GFuel Gauge
FIPGFormed In Place Gasket
FLFusible Link
F/PFuel Pump
FPUFuel Pressure Up
FrFront
F/WFlywheel
FW/DFlywheel Damper
FWDFront-Wheel-Drive
GASGasoline
GNDGround
GPSGlobal Positioning System
HACHigh Altitude Compensator
H/BHatchback

010QN-01
D32092
INCORRECT
INCORRECT
CORRECT
D25087
Looseness of Crimping
Core Wire
Terminal
Deformation
Pull Lightly 01-36
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
36 Author
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
ELECTRONIC CIRCUIT INSPECTION PROCEDURE
1. BASIC INSPECTION
(a) RESISTANCE MEASURING CONDITION OF ELECTRONIC PARTS
(1) Unless stated, all resistance is measured at an ambient temperature of 20C (68F). Resis-
tances measured may be outside the specifications if measured at high temperatures, i.e. im-
mediately after the vehicle has been running. Measurements should be made after the engine
has cooled down.
(b) HANDLING CONNECTORS
(1) When disconnecting a connector, first squeeze the
mating halves tightly together to release the lock,
then press the lock claw and separate the connec-
tor.
(2) When disconnecting a connector, do not pull on the
harnesses. Grasp the connector directly and sepa-
rate it.
(3) Before connecting the connector, check that there
are no deformed, damaged, loose or missing termi-
nals.
(4) When connecting a connector, press firmly until you
hear the lock close with a ºclickº sound.
(5) If checking the connector with a TOYOTA electrical
tester, check it from the backside (harness side) of
the connector using a mini test lead.
NOTICE:

As a waterproof connector cannot be checked from
the backside, check by connecting a sub-harness.

Do not damage the terminals by moving the inserted
tester needle.
(c) CHECKING CONNECTORS
(1) Checking when the connector is connected:
Squeeze the connector together to confirm that it is
fully inserted and locked.
(2) Checking when the connector is disconnected:
Check by pulling the wire harness lightly from the
backside of the connector. Look for unlatched termi-
nals, missing terminals, loose crimps or broken con-
ductor wires.
Check visually for corrosion, metallic or foreign ob-
jects and water; and bent, rusted, overheated, con-
taminated, and deformed terminals.
NOTICE:
When testing a gold-plated female terminal, always use a
gold-plated male terminal.

Z17808
Fig. 7
Sensor
B2
A
11 1
C
B1
1ECU
2
222
IN0383
Example
Ground
IN0384
Ground ECU Side
W/H Side
Ground
01-40- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
40 Author
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:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(2) Disconnect connector B and measure the resis-
tance between terminal 1 of connector A and the
body ground, and terminal 1 of connector B2 and
the body ground.
Fig. 7:
Tester ConnectionSpecified Condition
Connector A terminal 1 -
Body ground10 kW or higher
Connector B2 terminal 1 -
Body groundBelow 1 kW
If your results match the examples above, a short
circuit exists between terminal 1 of connector B2
and terminal 1 of connector C.
4. CHECK AND REPLACE ECU
NOTICE:

The connector should not be disconnected from the
ECU. Perform the inspection from the backside of the
connector on the wire harness side.

When no measuring condition is specified, perform
the inspection with the engine stopped and the igni-
tion switch ON.

Check that the connectors are fully seated. Check for
loose, corroded or broken wires.
(a) First check the ECU ground circuit. If it is faulty, repair it.
If it is normal, the ECU could be faulty. Replace the ECU
with a normal functioning one and check if the symptoms
occur. If the trouble symptoms stop, replace the ECU.
(1) Measure the resistance between the ECU ground
terminal and body ground.
Resistance: Below 1 W
(2) Disconnect the ECU connector. Check the ground
terminals (on the ECU side and wire harness side)
for evidence of bending, corrosion or foreign materi-
al. Lastly check the contact pressure of the female
terminals.

010QI-01
D25521
A
B
D25520
A
B
C
01-4
- INTRODUCTIONIDENTIFICATION INFORMATION
4 Author
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:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND SERIAL NUMBERS
1. VEHICLE IDENTIFICATION NUMBER
(a) The vehicle identification number is stamped on the ve-
hicle identification number plate and certification label, as
shown in the illustration.
A: Vehicle Identification Number Plate
B: Certification Label
2. ENGINE SERIAL NUMBER AND TRANSAXLE SERIAL
NUMBER
(a) The engine serial number is stamped on the cylinder
block of the engine and the transmission serial number is
stamped on the housing as shown in the illustration.
A: 3MZ-FE
B: 2AZ-FE
C: U140E, U151E, U151F, U241E