air condition TOYOTA HIGHLANDER 2001 Service Manual Online

2005 HIGHLANDER (EWD592U)
306
Manual Air Conditioning
Y
B 2IL2 12
4A 54F 7 A 9
P 5G
BR
MPX+ MPX-
B 8B7B1B9B6
IL2 15 IL24IL213 IL23IL211
M 5 4123
V
G
B
BR
R GB WL LG
AOF AOD SG- 4 S5- 4 TPO
A153J 123E 1
B 1B2
A 1A2IB2 8MPX1 MPX2
IB2 1
IF3 5
(
*4)
G 5
8
24 22 MPD1
MPD2
R
R
GR R
V SB BR
BR
OYGR
7 11
MPX1 MPX2
A17
Y
Y
Y
O A 14
DIM DIM
T1 56
G SB
G
V (
*3)
(
*3)4
S30(
A)
, S31(
B)
A10(
A)
, A11(
B)
A/C Control Assembly
Air Vent Mode Control Servo Motor Airbag Sensor Assembly
Gateway ECU
Power Window Master SW
wi th ECU Short ConnectorTelltale Light Assembly

2005 HIGHLANDER (EWD592U)
308
Manual Air Conditioning
1. Heater Blower Motor Operation
Current is applied at all times through the HTR fuse to TERMINAL 1 of the HEATER relay.
When the ignition SW is turned on, current flows through the HEATER fuse to TERMINAL 3 of the HEATER relay to
TERMINAL 5 to TERMINAL 8 of the blower control SW.
*Low speed operation
When the blower SW is moved to LO position, the current to TERMINAL 8 of the blower control SW flows to TERMINAL
1 to GROUND, causing the HEATER relay is turned on. This causes the current to flow from the HTR fuse to TERMINAL
1 of the HEATER relay to TERMINAL 2 to TERMINAL 2 of the blower motor to TERMINAL 1 to TERMINAL 1 of the
blower resistor to TERMINAL 4 to GROUND, causing the blower motor to rotate at low speed.
*Medium speed operation (Operation at M1, M2)
When the blower SW is moved to M1 position, the current to TERMINAL 8 of the blower control SW flows to TERMINAL
1 to GROUND, turns the HEATER relay on. This causes the current to flow from the HTR fuse to TERMINAL 1 of the
HEATER relay to TERMINAL 2 to TERMINAL 2 of the blower motor to TERMINAL 1 to TERMINAL 1 of the blower
resistor to TERMINAL 2 to TERMINAL 6 of the blower control SW to TERMINAL 1 to GROUND. At this time, the blower
resistance of the blower resistor is less than at low speed, so the blower motor rotates at medium low speed.
When the blower control SW is moved to M2 position, current flowing through the motor flows from TERMINAL 1 of the
blower resistor to TERMINAL 3 to TERMINAL 5 of the blower control SW to TERMINAL 1 to GROUND. At this time,
resistance of the blower resistor is less than at M1 position, so the blower motor rotates at medium high speed.
*High speed operation
When the blower SW is moved to HI position, the current flows to TERMINAL 8 of the blower control SW to TERMINAL
1 to GROUND and turns the HEATER relay on.
This causes the current to flow from the HTR fuse to TERMINAL 1 of the HEATER relay to TERMINAL 2 to TERMINAL 2
of the blower motor to TERMINAL 1 to TERMINAL 4 of the blower control SW to TERMINAL 1 to GROUND, causing the
blower motor to rotate at high speed.
2. Air Conditioning Operation
If the A/C control SW is turned on when the blower SW is set to on, A/C operation starts. However, when the mode SW is at
DEF or FOOT/DEF position, forcibly the air intake is set to FRESH mode and the A/C operates.
A3 Pressure SW
1-4 : Open with the pressure less than 2.0 kgf/cm2 (28 psi, 196 kpa) or above 32 kgf/cm2 (455 psi, 3138 kpa)
A10 (A) A/C Control Assembly
(A) 11-Ground : Always continuity
(A) 2-Ground : Approx. 12 volts with the ignition SW at ON position
(A)12-Ground : Always approx. 12 volts
(A)13-Ground : Approx. 12 volts with the ignitino SW at ACC or ON position
B8 Blower Resistor
1-3 : Approx. 0.22 W
1-2 : Approx. 0.69 W
1-4 : Approx. 1.69 W
B5 Blower Control SW
8-1 : Continuity with the blower SW at LO, M1, M2 or HI position
6-1 : Continuity with the blower SW at M1 position
5-1 : Continuity with the blower SW at M2 position
4-1 : Continuity with the blower SW at HI position
System Outline
Service Hints

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Manual Air Conditioning
: GROUND POINTS
CodeSee PageGround Points Location
ED48 (3MZ-FE)Rear Side of Cylinder Head
EE50 (2AZ-FE)Intake Side of Cylinder Block
EH48 (3MZ-FE)Under the Left HeadlightEH50 (2AZ-FE)Under the Left Headlight
IA52Left Cowl Side Panel
IB52Right Instrument Panel Brace
IC52Right Cowl Side Panel
: SPLICE POINTS
CodeSee PageWire Harness with Splice PointsCodeSee PageWire Harness with Splice Points
I654Engine WireI1454A/C Sub No.3 Wire
I1354A/C Sub No.1 Wire

'05 HIGHLANDER_U (L/O 0409)
375
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
If you perform maintenance by yourself,
be sure to follow the correct procedure
given in this Section.
You should be aware that improper or in-
complete servicing may result in operating
problems.
Performing do- it- yourself maintenance
during the warranty period may affect your
warranty coverage. Read the separate
Toyota Warranty statement for details and
suggestions.
This Section gives instructions only for
those items that are relatively easy for an
owner to perform. As explained in Section
6, there are still a number of items that
must be done by a qualified technician
with special tools.
For information on tools and parts for do-
it- yourself maintenance, see Parts and
toolsº on page 377 in this Section.
Utmost care should be taken when work-
ing on your vehicle to prevent accidental
injury. Here are a few precautions that
you should be especially careful to ob-
serve:CAUTION
When the engine is running, keep
hands, clothing, and tools away
from the moving fan and engine
drive belts. (Removing rings,
watches, and ties is advisable.)
Right after driving, the engine
compartmentÐthe engine, radiator,
exhaust manifold, power steering
fluid reservoir and spark plug
boots, etc.Ðwill be hot. So be care-
ful not to touch them. Oil, fluids
and spark plugs may also be hot.
If the engine is hot, do not remove
the radiator cap or loosen the drain
plugs to prevent burning yourself.
Do not leave anything that may
burn easily, such as paper or rags,
in the engine compartment.
Do not smoke, cause sparks or al-
low open flames around fuel or the
battery. Their fumes are flammable.
Do not get under your vehicle with
just the body jack supporting it. Al-
ways use automotive jack stands or
other solid supports.
Be sure that the ignition is off if
you work near the electric cooling
fans or radiator grille. With the
ignition on, the electric cooling fans
will automatically start to run if the
engine coolant temperature is high
and/or the air conditioning is on.
Use eye protection whenever you
work on or under your vehicle
where you may be exposed to flying
or falling material, fluid spray, etc.
Used engine oil contains potentially
harmful contaminants which may
cause skin disorders such as in-
flammation or skin cancer, so care
should be taken to avoid prolonged
and repeated contact with it. To re-
move used engine oil from your
skin, wash thoroughly with soap
and water.
Do not leave used oil within the
reach of children.
Dispose of used oil and filter only
in a safe and acceptable manner.
Do not dispose of used oil and fil-
ter in household trash, in sewers or
onto the ground. Call your dealer or
a service station for information
concerning recycling or disposal.
Do- it- yourself service
precautions

'05 HIGHLANDER_U (L/O 0409)
266
2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
Air conditioning system onÐ
Air conditioning system offÐ
The multi- information display indicates
the following information.
1. Outside temperature
2. Average vehicle speed
3. Average fuel consumption
4. Instantaneous fuel consumption
5. Driving time
6. Air conditioning system onÐThe air
conditioned temperature is displayed.
Air conditioning system offÐThe air
conditioned temperature is not dis-
played.
Every time you push the INFOº button,
the display toggles through this informa-
tion.
The displayed values in the multi- informa-
tion display indicate general driving condi-
tions. Accuracy varies with driving habits
and road conditions.
You can adjust the air conditioned temper-
ature while the multi- information is operat-
ing. 5 seconds has been passed after ad-
justing the temperature or pushing the
INFOº button, the display will be back to
the multi- information display.1. Outside temperature
(OUTSIDE TEMPº)
The outside temperature display indi-
cates the outside air temperature.
The displayed temperature ranges from
-22F (- 30C) up to 122F (50C).
If an abnormality exists in the connection
of the outside air temperature sensor,
- -Fº (- -Cº) will appear on the display.
If - -Fº (- -Cº) appears on the display,
contact your Toyota dealer.
There may be a case that - -Fº (- -Cº)
appears momentarily when the ignition is
quickly turned to ONº. It is normal if it
goes out soon.
2. Average vehicle speed
(AVG MPHº or AVG km/hº)
Average vehicle speed is calculated and
displayed based on total driving dis-
tance and total driving time with the
engine running.
The displayed value is updated every 10
seconds.
To reset the calculation, push the INFOº
button for more than 1 second.
Multi- information display

No. 4 Cylinder TDC/Compression
IN
EXA52470
Timing MarkPaint Mark
Timing Mark
Groove Paint Mark
A52471
A13325
- ENGINE MECHANICALVALVE CLEARANCE (2AZ-FE)
14-7
2500 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
Valve clearance (Cold):
ItemSpecified Condition
Intake0.19 to 0.29 mm (0.008 to 0.011 in.)
Exhaust0.30 to 0.40 mm (0.012 to 0.016 in.)
(b) Turn the crankshaft clockwise 1 revolution (360) and set
the No.4 cylinder to TDC/compression.
(c) Check only the valve indicated on the left.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record valve clearance measurements that are out
of the specified range. These measurements will be
used later to determine the size of the adjustment
shim to be installed.
Valve clearance (Cold):
ItemSpecified Condition
Intake0.19 to 0.29 mm (0.008 to 0.011 in.)
Exhaust0.30 to 0.40 mm (0.012 to 0.016 in.)
12. ADJUST VALVE CLEARANCE
NOTICE:
Be sure not to turn the crankshaft without the chain ten-
sioner.
(a) Turn the crankshaft clockwise 1 revolution (360) and set
the No. 1 cylinder to the TDC/compression.
(b) Place paint marks on the timing chain and camshaft tim-
ing gear sprocket.
(c) Remove the 2 bolts and chain tensioner.

A01082
- ENGINE MECHANICALVALVE CLEARANCE (2AZ-FE)
14-9
2502 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(h) Adjust the valve clearance.
(1) Using a micrometer, measure the thickness of the
removed lifter.
(2) Calculate the thickness of a new lifter so that the
valve clearance comes within the specified value.
AThickness of new lifter
BThickness of used lifter
CMeasured valve clearance
Valve clearance:
ItemSpecified Condition
IntakeA = B + (C - 0.24 mm (0.0094 in.))
ExhaustA = B + (C - 0.35 mm (0.0138 in.))
EXAMPLE: (Intake)
Measured valve clearance = 0.44 mm (0.0173 in.)
0.44 mm (0.0173 in.) - 0.24 mm (0.0094 in.) = 0.20 mm (0.0079 in.)
(Measured - Specification = Excess clearance)
Used shim measurement = 5.30 mm (0.2087 in.)
0.20 mm (0.0079 in.) + 5.30 mm (0.2087 in.) = 5.50 mm (0.2165 in.)
(Excess clearance + Used shim = Ideal new shim)
Closest new shim = 5.50 mm (0.2165 in.) = Shim No. º50º
(3) Select a new lifter with a thickness as close as pos-
sible to the calculated values.
HINT:

Lifters are available in 35 sizes in increments of 0.020 mm
(0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm
(0.2260 in.).

Refer to valve lifter selection chart on the following 2
pages.

*The titles given inside the components are the names of the terminals (terminal codes) and are not treated as being
abbreviations.
2005 HIGHLANDER (EWD592U)
17
ABBREVIATIONS D
ABBREVIATIONS
The following abbreviations are used in this manual.
2WD = Two Wheel Drive Vehicles
A/C = Air Conditioning
A/T = Automatic Transaxle
ABS = Anti-Lock Brake System
ACIS = Acoustic Control Induction System
ACM = Active Control Engine Mount
BEAN = Body Electronics Area Network
CAN = Controller Area Network
EC = Electrochromic
ECU = Electronic Control Unit
ESA = Electronic Spark Advance
EVAP = Evaporative Emission
IC = Integrated Circuit
J/B = Junction Block
LH = Left-Hand
O/D = Overdrive
R/B = Relay Block
RH = Right-Hand
SFI = Sequential Multiport Fuel Injection
SRS = Supplemental Restraint System
SW = Switch
TEMP. = Temperature
TRAC = Traction Control
VSC = Vehicle Stability Control
VSV = Vacuum Switching Valve
VVT = Variable Valve Timing
w/ = With
w/o = Without

- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-841
1031 Author
: Date
:
INSPECTION PROCEDURE
1 CHECK DTC
(a) Is DTC output for ABS?
Standard:
DTC is not outputA
DTC is outputB
B REPAIR CIRCUIT INDICATED BY OUTPUT
CODE
A
2 INSPECT CHECK IF SKID CONTROL ECU CONNECTOR IS SECURELY
CONNECTED
NG CONNECT CONNECTOR TO ECU
OK
3 INSPECT BATTERY
(a) Check the battery voltage.
Standard:
Tester ConnectionSpecified Condition
Battery terminal
((+) - (-))11 to 14 V
NG INSPECT CHARGING SYSTEM
OK

G24767
GND1IG1
Skid Control ECU
(harness side connector)
S27
05-842
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
1032 Author
: Date
:
4 INSPECT SKID CONTROL ECU TERMINAL VOLTAGE(IG1 TERMINAL)
WHEN USING HAND-HELD TESTER:
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine.
(c) Select the DATA LIST mode on the hand-held tester.
(d) Read the voltage condition output from the ECU displayed on the hand-held tester.
ItemMeasurement Item /
Range (Display)Normal Condition
IG VOLTAGEECU power supply voltage /
TOO LOW / NORMALNORMAL: 9.5 V or over
TOO LOW: Below 9.5 V
OK:
ºNormalº is displayed.
WHEN NOT USING HAND-HELD TESTER:
(a) Disconnect the skid control ECU connector.
(b) Turn the ignition switch ON position.
(c) Measure the voltage according to the value(s) in the table
below.
Standard:
Tester ConnectionSpecified Condition
S27-46 (IG1) - S27-32 (GND1)11 to 14 V
NG REPAIR OR REPLACE HARNESS OR
CONNECTOR
OK