engine TOYOTA HIGHLANDER 2001 Service Repair Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2001, Model line: HIGHLANDER, Model: TOYOTA HIGHLANDER 2001Pages: 2572, PDF Size: 34.8 MB
Page 2205 of 2572
010QL-02
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01-25
25 Author: Date:
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
A large number of ECU controlled systems are used in the HIGHLANDER. In general, ECU controlled sys-
tems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. How-
ever, most problem checking procedures only involve inspecting the ECU controlled system's circuits one
by one. An adequate understanding of the system and a basic knowledge of electricity is enough to perform
effective troubleshooting, accurate diagnoses and necessary repairs. Detailed information and trouble-
shooting procedures on major ECU controlled systems in this vehicle are outlined below:
SystemSee Page
1. SFI System (2AZ-FE)05-1
2. SFI System (3MZ-FE)05-362
3. Tire Pressure Warning System05-729
4. ABS with EBD & BA & TRAC & VSC System05-761
5. Electronic Controlled Automatic Transaxle [ECT] (U241E/U140F)05-876
6. Electronic Controlled Automatic Transaxle [ECT] (U151E/U151F)05-986
7. Air Conditioning System05-1 114
8. Supplement Restraint System05-1 194
9. Lighting System05-1526
10. Audio System05-161 1
11. Rear Seat Entertaiment System05-1690
12. Navigation System05-1749
13. Combination Meter05-1868
14. Power Window Control System05-1901
15. Power Door Lock Control System05-1934
16. Wireless Door Lock Control System05-1960
17. Sliding Roof System05-1974
18. Engine Immobiliser System05-1985
19. Theft Deterrent System05-2012
20. Multiplex Communication System05-2040
21. CAN Communication System05-2090
22. Cruise Control System05-2136
FOR USING OBD II SCAN TOOL OR HAND-HELD TESTER
Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should
be read thoroughly.
If the scan tool or tester cannot communicate with the ECU controlled systems when you have con-
nected the cable of the tester to the DLC3 with the ignition switch and tester turned ON, there is a prob-
lem on the vehicle side or tester side.
(1) If communication is normal when the tester is connected to another vehicle, inspect the diagnosis
data link line (Busline) or ECU power circuit of the vehicle.
(2) If communication is still impossible when the tester is connected to another vehicle, the problem
is probably in the tester itself. So perform the Self Test procedures outlined in the Tester Opera-
tor 's Manual.
Page 2209 of 2572
010QK-02
D25523
Rubber Attachment
- INTRODUCTIONREPAIR INSTRUCTION
01-21
21 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
VEHICLE LIFT AND SUPPORT LOCATIONS
1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP THE VEHICLE
(a) The vehicle must be unloaded before jacking up the vehicle. Never jack up/lift up a heavily loaded ve-
hicle.
(b) When removing heavy equipment such as the engine and transmission, the center of gravity of the
vehicle may shift. To stabilize the vehicle: place a balance weight in a location where it will not roll or
shift; or use a mission jack to hold the jacking support.
2. NOTICE FOR USING 4 POST LIFTS
(a) Follow the safety procedures outlined in its instruction manual.
(b) Use precautionary measures to prevent the free wheel beam from damaging tires or wheels.
(c) Use wheel chocks to secure the vehicle.
3. NOTICE FOR USING JACK AND SAFETY STAND
(a) Work in a flat area using wheel chocks at all times.
(b) Use a safety stand with a rubber attachment, as shown
in the illustration.
(c) Apply the jack and rigid rack to the specified location on
the vehicle.
(d) When jacking up the front wheels, release the parking
brake and place wheel chocks only behind the rear
wheels. When jacking up the rear wheels, place wheel
chocks only in front of the front wheels.
(e) The jack should not be used without the rigid rack.
(f) When jacking up only the front wheels or only the rear wheels, place wheel chocks on both sides of
the wheels touching the ground.
(g) When lowering the vehicle with its front wheels jacked up, release the parking brake and place wheel
chocks only in front of the rear wheels. When lowering a vehicle with its rear wheels jacked up, place
wheel chocks only behind the front wheels.
Page 2215 of 2572
010QJ-02
12
3
4 6
5
D25016
- INTRODUCTIONREPAIR INSTRUCTION
01-5
5 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
REPAIR INSTRUCTION
PRECAUTION
(b) HINTS ON OPERATIONS
1LooksAlways wear a clean uniform.
Hat and safety shoes must be worn.
2Vehicle protectionPrepare a grille cover, fender cover, seat cover and floor mat before starting the operation.
3Safe operation
When working with 2 or more persons, be sure to check safety for one another.
When working with the engine running, pay attention to providing ventilation for exhaust fumes in the
workshop.
If working on high temperature, high pressure, rotating, moving, or vibrating parts, wear appropriate safety
equipment and take extra care not to injure yourself or others.
When jacking up the vehicle, be sure to support the specified location with a safety stand.
When lifting up the vehicle, use appropriate safety equipment.
4Preparation of tools and
measuring gaugeBefore starting operation, prepare a tool stand, SST, gauge, oil, shop rag and parts for replacement.
5
Removal and installation,
disassembly and assem-
bly operations
Diagnose with a thorough understanding of proper procedures and of the reported problem.
Before removing the parts, check the general condition of the assembly and for deformation and damage.
When the assembly is complicated, take notes. For example, note the total number of electrical connections,
bolts, or hoses removed. Add matchmarks to insure re-assembly of components in the original positions.
Temporarily mark hoses and their fittings, if needed.
Clean and wash the removed parts if necessary and assemble them after a thorough check.
6Removed parts
Place the removed parts in a separate box to avoid mixing them up with the new parts or contaminating the
new parts.
As for non-reusable parts such as a gasket, an O-ring, and a self-locking nut, replace them with new ones
following the instructions in this manual.
Retain the removed parts for customer inspection, if requested.
Page 2225 of 2572
D25080
Negative (-)
Terminal
D31751
INCORRECT
- INTRODUCTIONREPAIR INSTRUCTION
01-15
15 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(i) WIRE HARNESS AND CONNECTOR
(1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All the con-
nectors in the system are a standard yellow color. If the SRS wire harness becomes discon-
nected or the connector becomes broken, repair or replace it.
2. ELECTRONIC CONTROL
(a) REMOVAL AND INSTALLATION OF BATTERY TERMI-
NAL
(1) Before performing electronic work, disconnect the
battery negative (-) terminal cable beforehand to
prevent component and wire damage caused by
accidental short circuits.
(2) When disconnecting and installing the terminal
cable, turn the ignition switch and lighting switch
OFF and loosen the terminal nut completely. Per-
form these operations without twisting or prying the
terminal. Remove the battery cable from battery
post.
(3) Clock settings, radio settings, DTCs and other data
are erased when the battery cable is removed. Be-
fore removing the battery cable, record any neces-
sary data.
(4) When disconnecting the battery's negative (-) ter-
minal cable, re-initialize the following systems after
the completion of the operation.
(b) HANDLING OF ELECTRONIC PARTS
(1) Do not open the cover or case of the ECU unless
absolutely necessary. If the IC terminals are
touched, the IC may be rendered inoperative by
static electricity.
(2) To disconnect electronic connectors, pull the con-
nector itself, not the wires.
(3) Be careful not to drop electronic components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced.
(4) When cleaning the engine with steam, protect the
electronic components, air filter and emission-re-
lated components from water.
(5) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
(6) When checking the continuity at the wire connector,
insert the tester probe carefully to prevent terminals
from bending.
Page 2226 of 2572
D01563
D25081
Spring Type Clamp
Clamp Track
D20025
01-16
- INTRODUCTIONREPAIR INSTRUCTION
16 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
3. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS
(a) PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Work in a place with good air ventilation and without any ignition sources, such as a welder, grind-
er, drill, electric motor or stove.
(2) Never work in a place such as a pit or near a pit because vaporized fuel will collect in those places.
(b) REMOVING AND INSTALLING OF FUEL SYSTEM PARTS
(1) Prepare a fire extinguisher before starting operation.
(2) To prevent static electricity, install a ground on the fuel changer, vehicle and fuel tank, and do
not spray the area with water. The work surface will become slippery. Do not clean up spills with
water as this will spread and gasoline and create a fire hazard.
(3) Never use any electric equipment like an electric motor or a working light, as they may create
sparks or high temperatures.
(4) Never use an iron hammer, as it may create sparks.
(5) Dispose of fuel-contaminated shop rags separately using a fire resistant container.
4. REMOVAL AND INSTALLATION OF ENGINE INTAKE
PARTS
(a) If any metal particle enters the inlet pass, this may dam-
age the engine.
(b) When removing and installing the inlet system parts, cov-
er the openings of the removed parts and engine open-
ings. Use clean shop rags, gummed tape, or other suit-
able materials.
(c) When installing the inlet system parts, check that no metal
particles have entered the engine or the installed part.
5. HANDLING OF HOSE CLAMPS
(a) Before removing the hose, check the clamp position so
that you can restore it in the same way.
(b) Replace deformed or dented clamps with new ones.
(c) When reusing a hose, attach the clamp on the clamp track
portion of the hose.
(d) For a spring type clamp, to spread the tabs slightly after
installation by pushing in the direction of the arrow marks
as shown in the illustration.
6. FOR VEHICLES EQUIPPED WITH MOBILE COMMU-
NICATION SYSTEMS
(a) Install the antenna as far away from the ECU and sensors
of the vehicle electronic systems as possible.
(b) Install an antenna feeder at least 20 cm (7.87 in.) away
from the ECU and sensors of the vehicle electronic sys-
tems. For details of the ECU and sensors locations, refer
to the section on applicable components.
(c) Keep the antenna and feeder separate from other wirings
as much as possible. This will prevent signals from the
communication equipment from affecting vehicle equip-
ment and vice-versa.
(d) Check that the antenna and feeder are correctly adjusted.
(e) Do not install any high-powered mobile communication
system.
Page 2227 of 2572
A82779
DLC3
1314 1516 12 11 10 9 12345678
TS
CG
- INTRODUCTIONREPAIR INSTRUCTION
01-17
17 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
7. FOR VEHICLES EQUIPPED WITH TRACTION CONTROL (TRAC) SYSTEM
(a) When testing with a 2-wheel drum tester such as a speedometer tester, a combination tester of the
speedometer and brake, a chassis dynamometer, or when jacking up the front wheels and driving the
wheels, always turn the TRAC system OFF beforehand via the TRAC OFF switch before testing.
NOTICE:
TRAC system OFF condition can be confirmed by the ºTRAC OFFº warning indicator light in the com-
bination meter.
8. FOR VEHICLES EQUIPPED WITH VEHICLE SKID
CONTROL (VSC) SYSTEM
(a) NOTICES WHEN USING DRUM TESTER
(1) Before beginning testing, disable the Vehicle Skid
Control system (VSC). To disable the VSC, turn the
ignition switch OFF and connect SST to terminals
TS and CG of DLC3.
SST 09843-18040
NOTICE:
Confirm that the VSC warning light blinks.
VSC system will be reset when the engine is re-
started.
For safety, secure the vehicle with restraint chains
while using a wheel dynamometer.
(b) NOTICES OF RELATED OPERATIONS TO VSC
(1) Do not carry out unnecessary installation and re-
moval as it might affect the adjustment of VSC re-
lated parts.
(2) Be sure to follow the instructions for work prepara-
tion and final confirmation of proper operation of the
VSC system.
Page 2228 of 2572
D25530
D25531
01-18
- INTRODUCTIONREPAIR INSTRUCTION
18 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
9. WHEN SERVICING FULL-TIME 4WD VEHICLES
(a) MEASURING POINTS FOR SPEEDOMETER TESTER
NOTICE:
Tester with a function of load setting cannot be used.
Inspection should be done in the front wheels.
Do not start, accelerate nor decelerate the vehicle suddenly.
Maximum vehicle speed must be below 60 km/h (when using free roller, it must be below 50
km/h).
Driving time should be within 1 minute.
(1) Place the front wheels onto the rollers.
(2) Set the rear wheels free by free rollers or rigid racks.
(3) Fasten the vehicle with the lock chain.
(4) Start the engine, and then measure the vehicle
speed by increasing the speed gradually in the D
range.
(5) After the measurement completion, decrease the
vehicle speed by brake gradually, and then stop the
vehicle.
(b) MEASURING POINTS FOR BRAKE TESTER
NOTICE:
Tester with a function of load measurement cannot be used
High-speed type brake cannot be used.
(1) Place the wheels to be measured (front or rear) onto the rollers.
(2) Shift the shift lever into neutral.
(3) Perform the measurement by driving the tester rollers.
HINT:
In case that the dragging force is over 10% of the load put on the axis, inspection of the wheel's rotating
condition should be done with both of the left and right axes jacked up. If no abnormality is found in the rotat-
ing condition, adhesive torque of the viscous coupling causes the excessive dragging fore and therefore it
means no problem exists in the vehicle.
Page 2229 of 2572
D25532
- INTRODUCTIONREPAIR INSTRUCTION
01-19
19 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) MEASURING POINTS FOR ON-VEHICLE BALANCER
(1) Jack up all 4 wheels with 2 post lifts.
(2) Fasten the vehicle by setting 2 pick-up stands in the
bottom of suspension arm's tip of the front wheels
or rear wheels to be measured.
(3) Support the vehicle with rigid racks so that vehicle
will not lean in the vehicle's front/rear direction.
(4) Release the parking brake.
(5) Check that no dragging force exists by turning each
wheel by hand.
(6) Set the wheel balancers.
(7) Measurement should be done by using both of en-
gine drive and wheel balancer roller drive.
NOTICE:
Start the engine, and then increase the vehicle speed
gradually in the D range.
Do not accelerate nor decelerate suddenly.
Deceleration should be done by brake gradually.
Take special care that the vehicle does not move.
Measurement should be done quickly.
10. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER
CAUTION:
If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause ove-
heating and create a fire hazard. To prevent this, observe the following precautions.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid idling the engine for more than 20 minutes.
(c) Avoid a spark jump test.
(1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as pos-
sible.
(2) While testing, never race the engine.
(d) Avoid a prolonged engine compression measurement.
Engine compression measurements must be performed as rapidly as possible.
(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and
create an extra load on the converter.
Page 2231 of 2572
010QP-01
01-46
- INTRODUCTIONTERMS
46 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )--ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal-
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection-
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position-
CTOXContinuous Trap Oxidizer-
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel InjectionDirect Injection (DI/INJ)
DIDistributor Ignition-
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Trouble Code
DTMDiagnostic Test Mode-
ECLEngine Coolant Level-
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionDistributorless Ignition (DLI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control-
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory-
FEPROMFlash Erasable Programmable Read Only Memory-
FFFlexible Fuel-
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
Page 2232 of 2572
- INTRODUCTIONTERMS
01-47
47 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module-
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel-Shutoff-
ISCIdle Speed Control-
KSKnock SensorKnock Sensor
MAFMass AirflowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure-
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface Temperature-
MVZManifold Vacuum Zone-
NVRAMNon-V olatile Random Access Memory-
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn-Board DiagnosticOn-Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OLOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module-
PNPPark/Neutral Position-
PROMProgrammable Read Only Memory-
PSPPower Steering Pressure-
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module-
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE-ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter-
SRIService Reminder Indicator-
SRTSystem Readiness Test-
STScan Tool-
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter