engine TOYOTA HIGHLANDER 2001 Service Repair Manual

I30328
w/o Navigation System
I38758
w/ Navigation System
I30337
ECU-B Fuse Engine Room J/B
F46779
- DIAGNOSTICSAIR CONDITIONING SYSTEM
05-1 119
1309 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) If the slower display is desired, press the FRONT DEF
switch and change it to stepped operation. Each time the
FRONT DEF switch is pressed, the display changes by 1
step.
4. CLEARING DTC
(a) To clear diagnostic trouble code, there are 2 ways.
(1) During sensor check, press the FRONT DEF switch
and REAR DEF switch at the same time.
(2) Pull the ECU-B fuse in engine room J/B for 20 sec.
or longer to clear the DTC memory.
5. DTC CHECK USING HAND-HELD TESTER
(a) Connect the hand-held tester to the DLC3.
(b) Power switch ON (ready).
(c) Read the DTC following the prompts on the tester screen.
Please refer to the hand-held tester operator's manual
for further details.
(d) Clear the DTCs.
HINT:
After repairing the malfunctions, clear the DTC.
(1) Connect the hand-held tester to DLC3.
(2) Turn the ignition switch to the ON position.
(3) Erase the DTCs following the prompts on the tester
screen.
HINT:
Refer to the hand-held tester operator's manual for further de-
tails.

3 2 1 45678
9 1 0 111 21 31 41 51 6
DLC3
A04550
- DIAGNOSTICSAIR CONDITIONING SYSTEM
05-1 121
1311 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
7. CHECK DLC3
(a) The vehicle's ECM uses ISO 9141-2 for communication.
The terminal arrangement of the DLC3 complies with
SAEJ1962 and matches the ISO 9141-2 format.
Terminal No.Connection/Voltage or ResistanceCondition
7Bus + Line/Pulse generationDuring transmission
4Chassis Ground - Body Ground/1 W or lessAlways
5Signal Ground - Body Ground/1 W or lessAlways
16Battery Positive - Body Ground/9 to 14 VAlways
8. DATA LIST
HINT:
From the DATA LIST displayed on the hand-held tester, you can read the values of the displays, sensors,
actuators and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is
one way to shorten labor time.
(a) Connect the hand-held tester to the DLC3.
(b) Turn the ignition switch to the ON position.
(c) From the display on the tester, select the ºDATA LISTº.
ALL:
ItemMeasurement Item / Display
(Range)Normal ConditionDiagnostic Note
A/C SIGA/C signal / ON or OFFA/C ON: ON-
A C:
ItemMeasurement Item/Display
(Range)Normal ConditionDiagnostic Note
ROOM TEMP
Room temperature sensor
/min.: -6.5C (20.3F)
max.: 57.25C (135.05F)
Actual room temperature-
AMBI TEMP SENS
Ambient temperature sensor
/min.: -23.3C (-9.94F)
max.: 65.95C (150.71F)
Actual ambient temperature-
AMBI TEMP
Adjusted ambient temperature
/min.: -30.8C (-23.44F)
max.: 50.8C (123.44F)
Actual ambient temperature-
EVAP TEMP
Evaporator temperature sensor
/min.: -29.7C (-21.46F)
max.: 59.55C (139.19F)
Actual evaporator temperature-
SOLAR SENS-DSolar sensor (Driver side)
/min.: 0 max.: 255Changes depending on brightness
(Driver side)-
COOLANT TEMP
Engine coolant temperature
/min.: 1.3C (34.34F)
max.: 90.55C (194.99F)
Actual engine coolant temperature-
SET TEMP-D
Set temperature
(Driver side)
/min.: 0 max.: 255Actual set temperature
(Driver side)-
A/M DAMP POS-D
Air mix damper position
(Driver side)
/min.: -14% max.: 113.5%Changes depending on the set
temperature (Driver side)-

F10016A
F10017A
F10018A
F10019A
F10020A
Body
Measurement
Diagrams
WRONG
CORRECT WRONG
Tip Cutter
Old
Spot
LocationsNew Spot
Locations
INTRODUCTIONIN-12
3. INSTALLATION
(a) PRE-WELDING MEASUREMENTS
(1) Always take measurements before installing under-
body or engine components to insure correct assem-
bly. After installation, confirm proper fit.
(b) WELDING PRECAUTIONS
(1) The number of welding spots should be as follows.
Spot weld: 1.3 X No. of manufacturer's spots.
Plug weld: More than No. of manufacturer's plugs.
(2) Plug welding should be done with a MIG (Metal Inert
Gas) welder. Do not gas weld or braze panels at areas
other than specified.
(c) POST-WELDING REFINISHING
(1) Always check the welded spots to insure they are se-
cure.
(2) When smoothing out the weld spots with a disc grind-
er, be careful not to grind off too much as this would
weaken the weld.
(d) SPOT WELD LOCATIONS
(1) Try to avoid welding over previous spots.
(e) SPOT WELDING PRECAUTIONS
(1) The shape of the welding tip point has an effect on the
strength of the weld.
(2) Always insure that the seams and welding tip are free
of paint.

051ZK-13
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-31
221 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
PROBLEM SYMPTOMS TABLE
SymptomSuspected AreaSee Page
Engine does not crank (does not start)
1. Starter
2. STARTER relay
3. PNP switch19-12
19-12
40-6
No initial combustion (does not start)
1. ECM power source circuit
2. Fuel pump control circuit
3. ECM05-312
05-349
01-36
No complete combustion (does not start)1. Fuel pump control circuit05-349
Difficult to start (engine cranks normally)
1. Starter signal circuit
2. Fuel pump control circuit
3. Compression05-235
05-349
14-1
Difficult to start with cold engine1. Starter signal circuit
2. Fuel pump control circuit05-235
05-349
Difficult to start with hot engine1. Starter signal circuit
2. Fuel pump control circuit05-235
05-349
High engine idle speed (poor idling)1. A/C signal circuit (Compressor circuit)
2. ECM power source circuit05-1 190
05-312
Low engine idle speed (poor idling)1. A/C signal circuit (Compressor circuit)
2. Fuel pump control circuit05-1 190
05-349
Rough idling (poor idling)1. Compression
2. Fuel pump control circuit14-1
05-349
Hunting (poor idling)1. ECM power source circuit
2. Fuel pump control circuit05-312
05-349
Hesitation/Poor acceleration (poor driveability)1. Fuel pump control circuit
2. A/T faulty05-349
05-904
Surging (poor driveability)1. Fuel pump control circuit05-349
Engine stalls soon after starting1. Fuel pump control circuit05-349
Engine stalls during A/C operation1. A/C signal circuit (Compressor circuit)
2. ECM05-1 190
01-36
Unable to refuel/Difficult to refuel1. ORVR system

7101E-06
- INSTRUMENT PANEL/METERCOMBINATION METER
71-1
3592 Author
: Date
:
COMBINATION METER
PROBLEM SYMPTOMS TABLE
Warning Lights:
SymptomSuspect AreaSee page
Check Engine warning light does not come on.
7. ECM
8. Wire Harness or Connector
9. Combination Meter Assy05-5
05-366
-
71-18
Discharge warning light does not come on.
1. ECM
2. Wire Harness or Connector
3. Combination Meter Assy05-5
05-366
-
71-18
Brake warning light does not come on.
1. Skid control ECU
2. Wire Harness or Connector
3. Combination Meter Assy05-761
-
71-18
ABS warning light does not come on.
1. ABS ECU
2. Wire Harness or Connector
3. Combination Meter Assy05-761
-
71-18
SRS warning light does not come on.
1. Airbag Sensor Assy Center
2. Wire Harness or Connector
3. Combination Meter Assy05-1200
-
71-18
Open Door warning light does not come on.
1. Refer to troubleshooting
2. Wire Harness or Connector
3. Combination Meter Assy05-1601
-
71-18
Fuel Level warning light does not come on.
1. Refer to troubleshooting
2. Wire Harness or Connector
3. Combination Meter Assy05-1893
-
71-18
Low Oil Pressure warning light does not come on.
1. Low Oil Pressure Warning Switch
2. Wire Harness or Connector
3. Combination Meter Assy71-3
-
71-18
Driver's seat belt warning light does not come on.
1. Refer to troubleshooting
2. Wire Harness or Connector
3. Combination Meter Assy05-1898
-
71-18
ºOIL LEVELº warning light does not come on.
1. Low Oil Level Sensor
2. Wire Harness or Connector
3. ECM
4. Combination Meter Assy05-5
05-366
-
05-5
05-366
71-18
ºTIRE AIR PRESSº warning light does not come on.
1. Wire Harness or Connector
2. Skid Control ECU
3. Combination Meter Assy-
05-761
71-18
Indicator Lights:
SymptomSuspect AreaSee page
Turn indicator light does not come on.
1. Turn Signal and Hazard Warning System
2. Wire Harness or Connector
3. Combination Meter Assy05-1533
-
71-18
High Beam indicator light does not come on.
1. Headlight Dimmer Switch
2. Wire Harness or Connector
3. Combination Meter Assy05-1533
-
71-18
Washer level indicator light does not come on.
1. Washer Level Warning Switch
2. Wire Harness or Connector
3. Combination Meter Assy-
-
71-18

BODY DIMENSIONS
(Three-Dimensional Distance)
Symbol Name Hole dia. Symbol Name Hole dia.mm (in.)
A, a
B, b
C, c
D, dRadiator upper support installation bolt
Headlight installation screw
Front end of front fender
Headlight installation screwÐ
Ð
Ð
ÐE, e
F, f
G, g
ÐFront fender installation bolt
Front fender installation bolt
Front fender installation bolt
ÐÐ
Ð
Ð
Ð
A-e A-E D-g D-G
or or C-c or or
a-E a-e d-G d-g
1,145 332 1,435 1,590 711
(45.08) (13.07) (56.50) (62.60) (27.99)
Vehicle Dimensions
1,479
(58.23)
709
(27.91)
1,613
(63.50)
365
(14.37)
1,511
(59.49)
1,258
(49.53)
599
(23.58)1,370
(53.94)
1,232
(48.50)1,084
(42.68)848
(33.39)179
(7.05)
1,453
(57.20)
DI-13
REFERENCE VALUE
ENGINE COMPARTMENT

2005 HIGHLANDER (EWD592U)
20
F RELAY LOCATIONS
[Engine Compartment]
[Instrument Panel]

2005 HIGHLANDER (EWD592U)
22
F RELAY LOCATIONS
2: Engine Room R/BEngine Compartment Left
[Inside Engine Room J/B] (See Page 20)

2005 HIGHLANDER (EWD592U)
23
F
3: Engine Room R/B No.3Engine Compartment Rear Left
(See Page 20)
5: ABS R/BEngine Compartment Rear Left (See Page 20)

2005 HIGHLANDER (EWD592U)
25
F
Fusible Link BlockEngine Compartment Left
[Inside Engine Room J/B] (See Page 20)