clutch TOYOTA HIGHLANDER 2001 Service Repair Manual

2005 HIGHLANDER (EWD592U)
300
Automatic Air Conditioning
2B
B 1B
5IK332
B- R B
TAM MPD2 MPD1
E 28
BR BR
E2 * 4 : w/o Navigation System * 3 : w/ Navigation System * 2 : 2AZ- FE * 1 : 3MZ- FE
(
*2) (
*1)BR
BR
BR
EE 5B
5A
6 EB2
A 1
2
1
A 3G 5 A17
MPX2 MPX1 22 244
11
BR
BR
V(
*3) G(
*3) R BRP 5
3E 13J 12
G
2A 1A YIB2 8
4F 7
4A 5
IL2 12
B 2
A 9MPX-
Y
IB2 1
IF3 5
A 10
B 6
B 18 B2 2A8
22C 2E3
IK3 18
B 1C 23
IK3 2
1
4
EH A2 13EB2 9
ED A A
J 7
W
J 2 78 MPX1 MPX2
SB
YV
GR G(
*4)
MPX2
MPX1
MPX1
LCK1
BR BRW- B G L
W- L
B- Y A 2
OY-G
Y- G
OMG CLT
Relay IK27
23 15 B- R
MPX+
A 21 9 BIL2 1B 29
SB GR
MPX- MPX+Y
HP MPX2ACMG
Diode
(
Cooling Fan) Y- G
(
*1) B 9(
A)
, B10(
B)
E 6(
B)
, E 7(
E)
, E 9(
C)
A10(
A)
, A11(
B)
S30(
A)
, S31(
B)
Dual
S28(
A)
, S29(
B)
C11(
A)
, C12(
B)
A/C Ambient Temp. Sensor
A/C Magnetic Clutch
A/C Lock Sensor Pr essure SW
A/C Contr ol Assembly
Air bag Sensor
Assembly
Body ECU
Combination MeterEngine Control Module
Gateway ECU
Ju nctio n
ConnectorJunction
Connector Power Window Master SW
with ECU
Short ConnectorShort Connector
E14 : * 1
E 9 : * 2
BR
1 2Engine Coolant
Temp. Sensor E 2
E 19THW
G- B G- B BR
W- B
W- B
BR
(
*2) (
*1) (
*1)(
*2)

2005 HIGHLANDER (EWD592U)
307
B 29B 2
1B C2323 15 2A8
IK27
2C 22E3
IK3 18 IL2 1
EB2 9
IK3 2
EH A4 1
EE EDA A2 13
A 2
A 3
J 7
J 2B- R Y
SB GR
O
B- YY- G
Y- G
MG CLT
Relay
MPX2
L
W- L G W- B
BR BR BR
(
*2) (
*1)
* 1 : 3MZ- FE
* 2 : 2AZ- FE
PRE LCK1ACMG
Diode
(
Cooling Fan) Y- G
(
*1)
18 BMPX1
B 6
A 10MPX2 MPX1B 9A 21
MPX+ MPX-
OWY
Y
Y
O* 3 : w/ Navigation System
* 4 : w/o Navigation System
E 5(
A)
, E 6(
B)
, E 9(
C)
C11(
A)
, C12(
B)
DualB 9(
A)
, B10(
B)
A/C Magnetic Clutch
A/C Lock Sensor
Pr essure SW
Body ECUCombination Meter
Engine Control Module
Junction
ConnectorJunction
Connector

I38769
ECM
LCK1 23
E9 W-L
A2
Cooler
Compressor
Assy
J7
J/C 1
2
A
ABR
BR (*2)
ED
EEBR (*1)
*1: 3MZ-FE
*2: 2AZ-FE 05-1 146
- DIAGNOSTICSAIR CONDITIONING SYSTEM
1336 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
DTC B1422/22 COMPRESSOR LOCK SENSOR CIRCUIT
CIRCUIT DESCRIPTION
The ECM and A/C amplifier communicate via BEAN.
This sensor sends 4 pulses per engine revolution to the ECM.
If the number ratio of the compressor speed divided by the engine speed is smaller than a predetermined
value, the ECM turns the compressor OFF. And the indicator flashes at about 1 second intervals.
DTC No.Detection ItemTrouble Area
All conditions below are detected for 3 secs or more

Cooler compressor assy (A/C magnetic clutch and lock sen-
sor)


Cooler compressor assy drive belt
B1422/22
All conditions below are detected for 3 secs. or more
(c) Engine speed: 450 rpm or more
(d) Ratio between engine and compressor speed deviates
20 % or more in comparison to normal operation

Cooler com ressor assy drive belt

Cooler compressor assy lock sensor

Harness and connector between cooler compressor assy and
ECM
20 % or more in comparison to normal operation.ECM

Multiplex communication circuit

ECM

A/C amplifier assy
WIRING DIAGRAM
05ITW-01

I40666
ON (Below 1.0 W) Low pressure side High pressure side
OFF
(10 kW or higher)OFF
(10 kW or higher) (2.0 kgfVcm
2, 28 psi) (32.0 kgfVcm2, 455 psi) 196 KPa 3,140 KPa
I41168
HP E61ECM
IK32
L G
1 A3
Pressure Switch
4
A
EH J2
J/CW-B
Dual
- DIAGNOSTICSAIR CONDITIONING SYSTEM
05-1 149
1339 Author
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:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
DTC B1423/23 PRESSURE SWITCH CIRCUIT
CIRCUIT DESCRIPTION
The ECM and A/C amplifier communicate via BEAN.
The pressure switch sends the appropriate signals to the A/C
amplifier when the A/C refrigerant pressure drops too low or
rises too high. When the A/C amplifier receives these signals,
it outputs signals through the A/C amplifier to turn the magnet
clutch relay off and turns the magnetic clutch off.
DTC No.Detection ItemTrouble Area
B1423/23

Open in pressure sensor circuit.

Abnormal refrigerant pressure.
below 196 kPa (2.0 kg/cm
2, 28 psi)
over 3,140 kPa (32.0 kgf/cm2, 455 psi)

Pressure switch

Harness or connector between cooler refrigerant liquid pipe A
(pressure switch) and ECM

Multiplex communication circuit

Refrigerant pipe line

ECM

A/C amplifier assy
WIRING DIAGRAM
05ITX-02

I40669
Pressure Switch Connector
Wire Harness View:
A3
05-1 150
- DIAGNOSTICSAIR CONDITIONING SYSTEM
1340 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
INSPECTION PROCEDURE
1 INSPECT REFRIGERANT PRESSURE
(a) Set the manifold gauge.
(b) Read the manifold gauge pressure when these conditions are established.
Test conditions:

Temperature at the air inlet with the switch set at RECIRC is 30 to 35°C (86 to 95°F)

Engine running at 1,500 rpm

Blower speed control switch at ºHIº position

Temperature control dial at ºCOOLº position

Air conditioning switch ON

Fully open doors
Standard:
Pressure on high pressure side:
1.37 to 1.57 MPa (13.9 to 16.0 kgfVcm
2, 198 to 228 psi)
HINT:
If the refrigerant pressure is below 196 KPa (2.0 kgfVcm
2, 28 psi), the refrigerant amount in the air condition-
ing cycle may have decreased significantly for reasons such as a gas leakage.
NG INSPECT AND REPAIR AIR CONDITIONING
CYCLE
OK
2 CHECK AIR CONDITIONING OPERATION
(a) Disconnect the pressure switch connector.
(b) Connect terminals 1 and 4 of the connector of the pres-
sure switch on the vehicle wire harness side using a ser-
vice wire.
(c) Start the engine.
(d) Turn the air conditioning switch on and check that the
magnet clutch is turned on.
(e) Check that the magnet clutch is turned off when discon-
necting terminals 1 and 4 (that are connected in the prior
step).
OK:
Terminals 1 and 4 connected: magnet clutch is on
Terminals 1 and 4 disconnected: magnet clutch is off
NG Go to step 3
OK
REPLACE PRESSURE SWITCH

- DIAGNOSTICSSFI SYSTEM (2AZ-FE)(From August, 2004)
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235 Author
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:
Hand-held Tester DisplayDiagnostic Note Normal Condition* Measurement Item/Range
(Display)
AF FT B1 S1
Short term fuel trim associated with bank
1, sensor 1/
Minimum: 0, Maximum: 1.999

Value less than 1 (0.000 to
0.999) = LEAN

Stoichiometric Air-Fuel Ratio=1

Value greater than 1 (1.001 to
1.999) = RICH
-
FUEL SYS #1
Fuel system status (Bank 1) /
OL or CL or OL DRIVE or
OL FAULT or CL FAULT
Idling after warming up: CL

OL (Open Loop) : Has not yet sa-
tisfied conditions to go closed
loop

CL (Closed Loop) : Using heated
oxygen sensor(s) as feed back
for fuel control

OL DRIVE: Open loop due to
driving conditions (fuel enrich-
ment)

OL FAULT: Open loop due to de-
tected system fault

CL FAULT: Closed loop but one
of heated oxygen sensors, which
is used for fuel control, is mal-
functioning
FC IDLIdle fuel cut/ ON or OFFFuel cut operation: ON
FC IDL = ON when throttle valve
is fully closed and engine speed is
over 1,500 rpm
MILMIL status/ ON or OFFMIL ON: ON-
STARTER SIGStarter signal/ ON or OFFCranking: ON-
A/C SIGA/C signal/ ON or OFFA/C ON: ON-
PNP SW [NSW]PNP switch signal/ ON or OFFP or N position: ON-
ELECT LOAD SIGElectrical load signal/ ON or OFFDefogger switch ON: ON-
STOP LIGHT SWStop lamp switch/ ON or OFF
Brake pedal depressed: ON

Brake pedal released: OFF-
PS OIL PRESS SWPower steering signal/ ON or OFF

While turning steering wheel: ON

While not turning steering wheel:
OFFIdle-up control is performed when
PS is ON
PS SIGNALPower steering signal/
ON or OFFWhen steering wheel is turnedThis signal is usually ON until Igni-
tion switch is turned OFF
FUEL PUMP / SPDFuel pump / speed status /
ON/H or OFF/M,LIdling: ON-
A/C MAG CLUTCHA/C magnet clutch status /
ON or OFFA/C magnet clutch ON: ON-
EVAP VSVEVAP VSV status control /
ON or OFFVSV operating: ONEVAP VSV is controlled by ECM
(ground side duty control)
VVT CTRL B1VVT control status (Bank 1) /
ON or OFFVVT system operation: ON-
IGNITIONIgnition counter/ Minimum: 0,
Maximum: 4000 to 400-
CYL #1, #2, #3, #4Misfire ratio of cylinder 1 to 4/
Minimum: 0 %, Maximum: 50 %0 %This item is displayed in only idling
MISFIRE LOADEngine load for first misfire range/
Minimum: 0 g/rev, Maximum: 3.98 g/rev.Misfire 0: 0 g/rev.'
MISFIRE RPMEngine RPM for first misfire range/
Minimum: 0 rpm, Maximum: 6,375 rpmMisfire 0: 0 rpm'
FC TAUFuel Cut TAU: Fuel cut during very light
load/ ON or OFFFuel cut operating: ON
Fuel cut is being performed under
very light load to prevent engine
combustion from becoming incom-
plete
CHECK MODECheck mode/ ON or OFFCheck mode ON: ONSee page 05-40

05-46
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)(From August, 2004)
236 Author
: Date
:
HINT:
*: If no conditions are specifically stated for ºldlingº, the shift lever is in the N or P position, the A/C switch
is OFF and all accessory switches are OFF.
2. ACTIVE TEST
HINT:
Performing the hand-held tester ACTIVE TEST allows relay, VSV, actuator and other items to be operated
without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to shorten
labor time. The DATA LIST can be displayed during the ACTIVE TEST.
(a) Warm up the engine.
(b) Turn the ignition switch OFF.
(c) Connect the hand-held tester or the OBD II scan tool to the DLC3.
(d) Turn the ignition switch ON.
(e) Turn ON the hand-held tester or the OBD II scan tool.
(f) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST.
(g) According to the display on tester, perform the ºACTIVE TEST.
Hand-held Tester DisplayTest DetailsDiagnostic Note
INJ VOL
[Test Details]
Control injection volume
Minimum: -12.5 %, Maximum: 25 %
[Vehicle Condition]
Engine speed: 3000 rpm or less
All injectors are tested at once

Injection volume is gradually
changed between -12.5 and 25
%
A/F CONTROL
[Test Details]
Control injection volume
-12.5 or 25 % (change the injection volume -12.5 % or 25 %)
[Vehicle Condition]
Engine speed: 3000 rpm or less
Following A/F CONTROL proce-
dure enables technician to check
and graph voltage outputs of both
A/F sensor and heated oxygen
sensor
For displaying the graph, enter
ºACTIVE TEST / A/F CONTROL /
USER DATAº, select ºAFS B1S1
and O2S B1S2º by pressing ºYESº
and push ºENTERº, Then press
ºF4º
EVAP VSV (ALONE)
[Test Details]
Activate EVAP VSV control
ON or OFF
-
A/C MAG CLUTCH
[Test Details]
Control A/C magnet clutch
ON or OFF
-
FUEL PUMP / SPD
[Test Details]
Control fuel pump
ON or OFF
-
VCUUM PUMP (ALONE)
[Test Details]
Vacuum pump
ON or OFF
-
VENT VALVE (ALONE)
[Test Details]
Vent valve
ON or OFF
-
VVT CTRL B1
[Test Details]
Activate VVT system (Bank 1)
ON or OFF
ON: Rough idle or engine stall

OFF: Normal engine speed
TC/TE1
[Test Details]
Connect TC and TE1
ON or OFF
-
FC IDL PROHBT
[Test Details]
Control idle fuel cut prohibit
ON or OFF
-

- DIAGNOSTICSSFI SYSTEM (3MZ-FE)(From August, 2004)
05-409
599 Author
: Date
:
Hand-held Tester DisplayDiagnostic Note Normal Condition * Measurement Item/Range
(Display)
FUEL SYS #1
Fuel system status (Bank 1) /
OL or CL or OL DRIVE or
OL FAULT or CL FAULT
Idling after warming up: CL

OL (Open Loop): Has not yet sa-
tisfied conditions to go closed
loop

CL (Closed Loop): Using heated
oxygen sensor(s) as feed back
for fuel control

OL DRIVE: Open loop due to
driving conditions (fuel enrich-
ment)

OL FAULT: Open loop due to de-
tected system fault

CL FAULT: Closed loop but one
of heated oxygen sensors, which
is used for fuel control, is mal-
functioning
FUEL SYS #2
Fuel system status (Bank 2) /
OL or CL or OL DRIVE or
OL FAULT or CL FAULT
Idling after warming up: CL

OL (Open Loop): Has not yet sa-
tisfied conditions to go closed
loop

CL (Closed Loop): Using heated
oxygen sensor(s) as feed back
for fuel control

OL DRIVE: Open loop due to
driving conditions (fuel enrich-
ment)

OL FAULT: Open loop due to de-
tected system fault

CL FAULT: Closed loop but one
of heated oxygen sensors, which
is used for fuel control, is mal-
functioning
FC IDLFuel cut idle/ ON or OFFFuel cut operation: ON
FC IDL = ON when throttle valve
is fully closed and engine speed is
over 1,500 rpm
MILMIL status/ ON or OFFMIL ON: ON'
STARTER SIGStarter signal/ ON or OFFCranking: ON'
A/C SIGA/C signal/ ON or OFFA/C ON: ON'
PNP SW [NSW]PNP switch signal/ ON or OFFP or N position: ON'
ELECT LOAD SIGElectrical load signal/
ON or OFF
Taillamp switch ON: ON

Defogger switch ON: ON'
STOP LIGHT SWStop light switch/
ON or OFF
Brake pedal depressed: ON

Brake pedal released: OFF'
PS OIL PRESS SWPower steering oil pressure switch
signal/ ON or OFF

While turning the steering wheel:
ON

While not turning the steering
wheel: OFF
Idle-up control is performed when
PS is ON
PS SIGNALPower steering signal/
ON or OFFWhen steering wheel is turnedThis signal is usually ON until the
Ignition switch is turned OFF
INTAKE CTL VSV1VSV status for intake control (bank
1)/ ON or OFFVSV operation: ON'
INTAKE CTL VSV 2VSV status for intake control (bank
2)/ ON or OFFVSV operation: ON'
FUEL PUMP / SPDFuel pump/speed status/
ON/H or OFF/M, LIdling: ON'
A/C MAG CLUTCHA/C magnet clutch status/
ON or OFFA/C magnet clutch ON: ON'

- DIAGNOSTICSSFI SYSTEM (3MZ-FE)(From August, 2004)
05-41 1
601 Author
: Date
:
Hand-held Tester DisplayDiagnostic Note Test Details
INTAKE CTL VSV1
[Test Details]
Activate VSV for intake control
ON or OFF
'
CAN CTRL VSV
[Test Details]
Activate VSV for canister control
ON or OFF
'
EVAP VSV (ALONE)
[Test Details]
Activate EVAP VSV control
ON or OFF
'
A/C MAG CLUTCH
[Test Details]
Control A/C magnet clutch
ON or OFF
'
FUEL PUMP / SPD
[Test Details]
Control the fuel pump
ON or OFF
'
VVT CTRL B1
[Test Details]
Active VVT system (bank 1)
ON or OFF
ON: Rough idle or engine stall

OFF: Normal engine speed
VVT CTRL B2
[Test Details]
Active VVT system (bank 2)
ON or OFF
ON: Rough idle or engine stall

OFF: Normal engine speed
ACM INHIBIT
[Test Details]
Control ACM inhibit
ON or OFF
'
TC/TE1
[Test Details]
Connect TC and TE1
ON or OFF
'
FC IDL PROHBT
[Test Details]
Control idle fuel cut prohibit
ON or OFF
'

I30520
ECM
ACMG 2
E6 O
IK3 Magnetic Clutch Relay
9 18 From Fan No. 3
Relay
Y-G
Y-G
EB2
B-Y
3 2
3 8
A2
A/C Magnetic
Clutch and
Lock Sensor 3 2 1
52C
2E 2A B-R
IK27Engine Room J/B
Y From
Battery 05-1 190
- DIAGNOSTICSAIR CONDITIONING SYSTEM
1380 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
COMPRESSOR CIRCUIT
CIRCUIT DESCRIPTION
The ECM and A/C amplifier communicate via BEAN.
The A/C amplifier assy outputs the magnetic clutch ON signal to the ECM.
Receiving this signal, the ECM sends a signal through terminal ACMG and switches the magnetic clutch
relay ON, thus turning on the magnetic clutch.
WIRING DIAGRAM
05IU8-01