o2 sensor TOYOTA HIGHLANDER 2001 Service Repair Manual
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Page 2213 of 2572
i
2005 HIGHLANDER Navigation from Aug. '04 Prod. (OM48539U)
Introduction
Thank you for your purchase of the Navigation System. Please read this manual carefully to ensure proper use. Keep this manual
in your vehicle at all times.
The Navigation System is one of the most technologically advanced vehicle accessories ever developed. The system receives satellite signals
from the Global Positioning System (GPS) operated by the U.S. Department of Defense. Using these signals and other vehicle sensors, the
system indicates your present position and assists in locating a desired destination.
The navigation system is designed to select efficient routes from your present starting location to your destination. The system is designed
to direct you to a destination that is unfamiliar to you in an efficient manner. The system uses the maps of DENSO. The calculated routes
may not be the shortest nor the least traffic congested. Your own personal local knowledge or short cutº may at times be faster than the calcu-
lated routes.
The navigation system's database includes about 75 Point of Interest categories to allow you to easily select destinations such as restaurants
and banks. If a destination is not in the database, you can enter the street address or a major intersection close to it and the system will guide
you there. The system will provide both a visual map and audio instructions. The audio instructions will announce the distance remaining
and the direction to turn in approaching a fork or intersection. These voice instructions will help you keep your eyes on the road and are timed
to provide enough time to allow you to maneuver, change lanes or slow down.
Please be aware that all current vehicle navigation systems have certain limitations that may affect their ability to perform properly.
The accuracy of the vehicle's position depends on the satellite condition, road configuration, vehicle condition or other circumstan-
ces. For more information on the limitations of the system, refer to pages 9 through 11.
Page 2220 of 2572
01-10
- INTRODUCTIONREPAIR INSTRUCTION
10 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
HINT:
The HIGHLANDER is equipped with a Supplemental Restraint System (SRS) and seat belt pretensioner.
Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly
deploy during servicing and lead to serious injury.
Furthermore, if a mistake is made when servicing the SRS, it is possible that the SRS may fail to operate
properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to
read the following section carefully.
(a) GENERAL NOTICE
(1) Malfunction symptoms of the SRS are difficult to confirm so the Diagnostic Trouble Codes (DTCs)
become the most important source of information when troubleshooting. When troubleshooting
the SRS, always check the DTCs before disconnecting the battery (see page 05-1215).
(2) To avoid serious injury, servicing the SRS must be started at least 90 seconds after:
The ignition switch is turned to the LOCK position.
The negative (-) terminal cable is disconnected from the battery.
(The SRS is equipped with a back-up power source. If work is started within 90 seconds of dis-
connecting the negative (-) terminal cable from the battery, the SRS may deploy.)
Disconnecting the negative (-) terminal cable will erase the memory of all vehicle systems. Initial-
ize the systems after disconnecting/reconnecting the cable.
CAUTION:
Never use a back-up power source (battery or other) in an attempt to avoid erasing system memory.
The back-up power source inadvertently may inadvertently power the SRS and cause it to deploy.
(3) In minor collisions where the SRS does not deploy, the horn button assembly, instrument panel
passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly and seat
belt pretensioner should be inspected before further use of the vehicle (see pages 60-19,
60-31, 60-40, 60-46, and 61-8).
(4) Never use SRS parts from another vehicle. When replacing parts, use new parts.
(5) Before repairs, remove the airbag sensor if impacts are likely to be applied to the sensor during
repairs.
(6) Never disassemble and repair the airbag sensor assembly, horn button assembly, instrument
panel passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly
or seat belt pretensioner.
(7) Replace the center airbag sensor assembly, side airbag sensor assembly, horn button assembly
or the instrument panel passenger airbag assembly, front seat airbag assembly or curtain shield
airbag assembly if: 1) damage has occurred from being dropped, or 2) cracks, dents or other
defects in the case, bracket or connector are present.
(8) Do not directly expose the airbag sensor assembly, the horn button assembly, the instrument
panel passenger airbag assembly, front seat airbag assembly, the curtain shield airbag assem-
bly or the seat belt pretensioner to hot air or flames.
(9) Use a voltmeter/ohmmeter with high impedance (10 kW/V minimum) for troubleshooting electri-
cal circuits.
(10) Information labels are attached to the SRS components. Follow the instructions on the labels.
(11) After work on the SRS is completed, check the SRS warning light (see page 05-1207).
Page 2224 of 2572
D30924
Example:
NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER
D30370
Example:
NEVER USE AN OHMMETER ON AN AIRBAG OR PRETENSIONER 01-14
- INTRODUCTIONREPAIR INSTRUCTION
14 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(g) SEAT BELT PRETENSIONER
(1) Never measure the resistance of the seat belt pretensioner. This may cause the seat belt preten-
sioner to activate, which is very dangerous.
(2) Never disassemble the seat belt pretensioner.
(3) Never install the seat belt pretensioner on another vehicle.
(4) Store the seat belt pretensioner in area where the ambient temperature is below 80°C (176°F),
the humidity is not high and electrical noise is not nearby.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors
(2 pins). These connectors contain shorting springs. This feature reduces the possibility of the
airbag deploying due to currents entering the squib wiring.
(6) When disposing of a vehicle or the seat belt pretensioner unit by itself, the seat belt pretensioner
should be activated before disposal (see page 61-8). Activate in a safe place away from electri-
cal noise.
(7) The seat belt pretensioner is hot after being activated, so allow some time for it to cool down suffi-
ciently before disposal. Never apply water to cool down the seat belt pretensioner.
(8) Oil or water should not be put on the front seat outer belt, and the front seat outer belt should
not be cleaned with detergents of any kind.
(h) AIRBAG SENSOR ASSEMBLY
(1) Never reuse an airbag sensor assembly that has been involved in a collision where the SRS has
deployed.
(2) The connectors to the airbag sensor assembly should be connected or disconnected with the
sensor mounted on the floor. If the connectors are connected or disconnected while the airbag
sensor assembly is not mounted to the floor, it could cause accidental deployment of the SRS.
(3) Work must be started at least 90 seconds after the ignition switch is turned to the LOCK position
and the negative (-) terminal cable is disconnected from the battery, even if only loosening the
set bolts of the airbag sensor assembly.
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 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
Page 2233 of 2572
01-48
- INTRODUCTIONTERMS
48 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U) TCM
Transmission Control ModuleTransmission ECU, ECT ECU
TPThrottle PositionThrottle Position
TRTransmission Range-
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree-W ay Catalytic Converter
Three-W ay Catalytic (TWC)
Manifold Converter
CC
RO
TWC+OCThree-W ay + Oxidation Catalytic ConverterCCR + CCo
VA FVolume AirflowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor
WOTWide Open ThrottleFull Throttle
WU-OCWarm Up Oxidation Catalytic Converter-
WU-TWCWarm Up Three-Way Catalytic Converter-
3GRThird Gear-
4GRFourth Gear-
Page 2237 of 2572
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01-29
29 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE
HINT:
The diagnostic system in the HIGHLANDER has various functions.
The first function is the Diagnostic Trouble Code (DTC) check. A DTC is a code stored in the ECU
memory whenever a malfunction in the signal circuits to the ECU occurs. In a DTC check, a previous
malfunction's DTC can be checked by a technician during troubleshooting.
Another function is the Input Signal Check, which checks if the signals from various switches are sent
to the ECU correctly.
By using these functions, the problem areas can be narrowed down and troubleshooting is more effec-
tive. Diagnostic functions are incorporated in the following systems in the HIGHLANDER:
SystemDiagnostic Trouble
Code CheckInput Signal Check
(Sensor Check)Diagnotis Test Mode
(Active Test)
SFI System
(with Check Mode)
ABS with EBD & BA & TRAC & VSC System
Electronic Controlled Automatic Transaxle [ECT]
(with Check Mode)
Air Conditioning System
Supplement Restraint System
Power Window Control System
Power Door Lock Control System
Wireless Door Lock Control System
Engine Immobiliser System
Multiplex Communication System
Cruise Control System
In the DTC check, it is very important to determine whether the problem indicated by the DTC is: 1 still
occurring, or 2 occurred in the past but has since returned to normal. In addition, the DTC should be
compared to the problem symptom to see if they are related. For this reason, DTCs should be checked
before and after confirmation of symptoms (i.e., whether or not problem symptoms exist) to determine
current conditions, as shown in the table below.
Never skip the DTC check. Failure to check DTCs may, depending on the case, result in unnecessary
troubleshooting for systems operating normally or lead to repairs not pertinent to the problem. Follow
the procedures listed above in the correct order.
A flow chart showing how to proceed with troubleshooting using the DTC check is shown below. Direc-
tions from the flow chart will indicate should be performed DTC troubleshooting or to the troubleshoot-
ing of each problem symptom.
1 DTC CHECK
2 MAKE A NOTE OF DTCS DISPLAYED AND THEN CLEAR THE MEMORY
3 SYMPTOM CONFIRMATION
aSymptoms exist
bNo symptoms exist
a Go to step 5
Page 2239 of 2572
B71602
Vibrate Slightly
Shake Slightly
Vibrate
Slightly
D25084
Malfunction
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01-31
31 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
SYMPTOM SIMULATION
HINT:
The most difficult case in troubleshooting is when no problem symptoms occur. In such cases, a thorough
customer problem analysis must be carried out. A simulation of the same or similar conditions and environ-
ment in which the problem occurred in the customer's vehicle should be carried out. No matter how much
skill or experience a technician has, troubleshooting without confirming the problem symptoms will lead to
important repairs being overlooked and mistakes or delays.
For example:
With a problem that only occurs when the engine is cold or occurs as a result of vibration caused by the road
during driving, the problem can never be determined if the symptoms are being checked on a stationary ve-
hicle or a vehicle with a warmed-up engine.
Vibration, heat or water penetration (moisture) is difficult to reproduce. The symptom simulation tests below
are effective substitutes for the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must be con-
firmed. First, narrow down the possible problem circuits according to the symptoms. Then, connect the tester
and carry out the symptom simulation test, judging whether the circuit being tested is defective or normal.
Also, confirm the problem symptoms at the same time. Refer to the problem symptoms table for each system
to narrow down the possible causes.
1. VIBRATION METHOD: When vibration seems to be
the major cause.
(a) PART AND SENSOR
(1) Apply slight vibration with a finger to the part of the
sensor considered to be the cause of the problem
and check whether or not the malfunction occurs.
HINT:
Applying strong vibration to relays may open relays.
(b) CONNECTORS
(1) Slightly shake the connector vertically and horizon-
tally.
(c) WIRE HARNESS
(1) Slightly shake the wire harness vertically and hori-
zontally.
The connector joint and fulcrum of the vibration are
the major areas that should be checked thoroughly.
2. HEAT METHOD: If the problem seems to occur when
the area in question is heated.
(a) Heat the component that is the possible cause of the mal-
function with a hair dryer or similar device. Check if the
malfunction occurs.
NOTICE:
Do not heat to more than 60C (140F). Exceeding this
temperature may damage components.
Do not apply heat directly to the parts in the ECU.
Page 2241 of 2572
Detection Item
Indicates the system or details of the
problem.Trouble Area
Indicates the suspect areas of
the problem.
Detection Item DTC No.
(See page)Trouble AreaSRS
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness
B0103/12
(05-132) B0102/11
(05-128)
DIAGNOSTIC TROUBLE CODE CHART
If a malfunction code is displayed during the DTC check, check the circuit for that code listed in the table
below (Proceed to the page given for that circuit).
Short in D squib circuit
Open in D squib circuit
B0101/14
(05-124)
Short in D squib circuit (to ground)
Short in D squib circuit (to B+)
Warning Light
ON
ON
ON
ON Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness
Steering wheel pad (squib)
Spiral cable
Airbag sensor assembly
Wire harness
B0105/53
(05-136)ON
Airbag sensor assembly
Wire harness B0106/54 Open in P squib circuit
Airbag sensor assembly
Wire harness Short in P squib circuit (to Ground)ON
ON B0100/13
(05-1 19)
Short in P squib circuit Front passenger airbag assembly (squib)
Airbag sensor assembly
Wire harness
Front passenger airbag assembly (squib)
Front passenger airbag assembly (squib)
Page or Instructions
Indicates the page where the inspection proce-
dures for each circuit is to be found, or gives
instructions for checking and repairs. DTC No.
Indicates the diagnostic trouble code.
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS01-33
33 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
DIAGNOSTIC TROUBLE CODE CHART
Use Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the table below to determine the trouble
area and proper inspection procedure. The Supplemental Restraint System (SRS) diagnostic trouble code
chart is shown below as an example.