length TOYOTA HIGHLANDER 2001 Service Repair Manual

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2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)

Backing with a trailer is difficult and
requires practice. Grip the bottom of
the steering wheel and move your hand
to the left to move the trailer to the
left. Move your hand to the right to
move the trailer to the right. (This pro-
cedure is generally opposite to that
when backing without a trailer.) Also,
just turn the steering wheel a little at
a time, avoiding sharp or prolonged
turning. Have someone guide you when
backing to reduce the risk of an acci-
dent.

Because stopping distance may be in-
creased, vehicle- to- vehicle distance
should be increased when towing a
trailer. For each 16 km/h (10 mph) of
speed, allow at least one vehicle and
trailer length between you and the ve-
hicle ahead. Avoid sudden braking as
you may skid, resulting in jackknifing
and loss of control. This is especially
true on wet or slippery surfaces.

Avoid jerky starts or sudden accelera-
tion.

Avoid jerky steering and sharp turns.
The trailer could hit your vehicle in a
tight turn. Slow down before making a
turn to avoid the necessity of sudden
braking.

Remember that when making a turn,
the trailer wheels will be closer than
the vehicle wheels to the inside of the
turn. Therefore, compensate for this by
making a larger than normal turning
radius with your vehicle.

Crosswinds and rough roads will ad-
versely affect handling of your vehicle
and trailer, causing sway. Pay attention
to the rear from time to time to pre-
pare yourself for being passed by large
trucks or buses, which may cause your
vehicle and trailer to sway. If swaying
happens, firmly grip the steering wheel
and reduce speed immediately but
gradually. Never increase speed. Steer
straight ahead. If you make no extreme
correction with the steering or brakes,
the vehicle and trailer will stabilize.

Be careful when passing other ve-
hicles. Passing requires considerable
distance. After passing a vehicle, do
not forget the length of your trailer and
be sure you have plenty of room be-
fore changing lanes.

In order to maintain engine braking effi-
ciency, do not use overdrive.

Because of the added load of the trail-
er, your vehicle's engine may overheat
on hot days (at temperatures over
30C [85F]) when going up a long or
steep grade with a trailer. If the engine
coolant temperature gauge indicates
overheating, immediately turn off the air
conditioning (if in use), pull off the road
and stop in a safe spot. Refer to If
your vehicle overheatsº on page 336 in
Section 4.

Always place wheel blocks under both
the vehicle and trailer wheels when
parking. Apply the parking brake firmly.
Put the transmission in Pº. Avoid park-
ing on a slope with a trailer, but if it
cannot be avoided, do so only after
performing the following:
1. Apply the brakes and hold.
2. Have someone place wheel blocks un-
der both the vehicle and trailer wheels.
3. When the wheel blocks are in place,
release your brakes slowly until the
blocks absorb the load.
4. Apply the parking brake firmly.
5. Shift into Pº and turn off the engine.

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When restarting out after parking on a
slope:
1. With the transmission in Pº position,
start the engine. Be sure to keep the
brake pedal depressed.
2. Shift into gear.
3. Release the parking brake and brake
pedal and slowly pull or back away
from the wheel blocks. Stop and apply
your brakes.
4. Have someone retrieve the blocks.CAUTION

Do not exceed 72 km/h (45 mph) or
the posted towing speed limit,
whichever is lower. Because insta-
bility (swaying) of a towing vehicle-
trailer combination usually in-
creases as the speed increases, ex-
ceeding 72 km/h (45 mph) may
cause loss of control.

Slow down and downshift before
descending steep or long downhill
grades. Do not make sudden down-
shifts.

Avoid holding the brake pedal down
too long or too frequently. This
could cause the brakes to overheat
and result in reduced braking effi-
ciency.
Improving fuel economy is easyÐjust take
it easy. It will help make your vehicle last
longer, too. Here are some specific tips
on how to save money on both fuel and
repairs:

Keep your tires inflated at the cor-
rect pressure. Underinflation causes
tire wear and wastes fuel. See page
385 in Section 7- 2 for instructions.

Do not carry unneeded weight in
your vehicle. Excess weight puts a
heavier load on the engine, causing
greater fuel consumption.

Avoid lengthy warm- up idling. Once
the engine is running smoothly, begin
drivingÐbut gently. Remember, howev-
er, that on cold winter days this may
take a little longer.

Keep the automatic transmission
overdrive turned on when engine
braking is not required. Driving with
the overdrive off will reduce the fuel
economy. (For details, see Automatic
transmissionº on page 147 in Section
1- 7.)

Accelerate slowly and smoothly.
Avoid jackrabbit starts. Get into high
gear as quickly as possible.
How to save fuel and make
your vehicle last longer

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2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
Model:
2AZ- FE and 3MZ- FE
Type:
2AZ- FE engine
4 cylinder in line, 4 cycle, gasoline
3MZ- FE engine
6 cylinder V type 4 cycle, gasoline
Bore and stroke, mm (in.):
2AZ- FE engine
88.5
96.0 (3.48
3.78)
3MZ- FE engine
92.0
83.0 (3.62
3.27)
Displacement, cm
3 (cu. in.):
2AZ- FE engine
2362 (144.1)
3MZ- FE engine
3311 (202.1)
Dimensions and weights
Overall length mm (in.)
Overall width mm (in.)
Overall height
*
1mm (in.)
Wheelbase mm (in.)
Front tread mm (in.)
Rear tread mm (in.)
Vehicle capacity
weight (occupants
+ luggage) kg (lb.)Two- wheel drive models Four- wheel drive models
4690 (184.6)
4690 (184.6)
1825 (71.9) 1825 (71.9)
1690 (66.5)
*
2
1745 (68.7)*
3
2715 (106.9) 2715 (106.9)
1580 (62.2) 1575 (62.0)
1565 (61.6) 1555 (61.2)
390 (860)
*
4
526 (1159)*
5390 (860)*
4
526 (1159)*
5
*
1
: Unladen vehicle*
2: Without roof rails*
3: With roof rails*
4: Without third seat*
5: With third seat*
6: 2AZ- FE engine*
7: 3MZ- FE engine*
8: Without towing package*
9: With towing package1680 (66.1)
*
2
1735 (68.3)*
3
Towing capacity
(trailer weight +
cargo weight) kg (lb.)680 (1500)*
6, 8
1360 (3000)*
6, 9
907 (2000)*
7, 8
1585 (3500)*
7, 9
680 (1500)*
6, 8
1360 (3000)*
6, 9
907 (2000)*
7, 8
1585 (3500)*
7, 9
Engine

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Ta b
Buckle
Adjust the seat as needed and sit up
straight and well back in the seat. To
fasten your belt, pull it out of the re-
tractor and insert the tab into the
buckle.
You will hear a click when the tab locks
into the buckle.
The seat belt length automatically adjusts
to your size and the seat position.
The retractor will lock the belt during a
sudden stop or on impact. It also may
lock if you lean forward too quickly. A
slow, easy motion will allow the belt to
extend, and you can move around freely.When a passenger 's shoulder belt is com-
pletely extended and is then retracted
even slightly, the belt is locked in that
position and cannot be extended. This fea-
ture is used to hold the child restraint
system securely. (For details, see Child
restraintº on page 91 in this Section.) To
free the belt again, fully retract the belt
and then pull the belt out once more.
If the seat belt cannot be pulled out of the
retractor, firmly pull the belt and release
it. You will then be able to smoothly pull
the belt out of the retractor.CAUTION

After inserting the tab, make sure
the tab and buckle are locked and
that the belt is not twisted.

Do not insert coins, clips, etc. in
the buckle as this may prevent you
from properly latching the tab and
buckle.

If the seat belt does not function
normally, immediately contact your
Toyota dealer. Do not use the seat
until the seat belt is fixed, because
it cannot protect an adult occupant
or your child from injury.
Ta k e u p
slack
To o h i g h
Keep as low on
hips as possible
Adjust the position of the lap and
shoulder belts.
Position the lap belt as low as possible
on your hipsÐnot on your waist, then ad-
just it to a snug fit by pulling the shoulder
portion upward through the latch plate.
ÐFastening front and rear
seat belts

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To stow the third seat seat belt, insert
the tabs into the slot as shown above.
Make sure the tabs are securely locked
in the slot.
Seat belt must be stowed before you fold
the seatback. (See ÐFolding down third
seatº on page 51 in this Section.)
NOTICE
Stow the third seat seat belt when
not in use.
If your seat belts cannot be fastened se-
curely because they are not long enough,
a personalized seat belt extender is avail-
able from your Toyota dealer free of
charge.
Please contact your local Toyota dealer to
order the proper required length for the
extender. Bring the heaviest coat you ex-
pect to wear for proper measurement and
selection of length. Additional ordering in-
formation is available at your Toyota deal-
er.
CAUTION
When using the seat belt extender,
observe the following precautions.
Failure to follow these instructions
could reduce the effectiveness of the
seat belt restraint system in case of
an accident, increasing the chance of
personal injury.

Remember that the extender pro-
vided for you may not be safe when
used on a different vehicle, for
another person, or at a different
seating position than the one origi-
nally intended.

If the seat belt extender has been
connected to the driver 's seat belt
buckle without wearing the seat belt
when using the extender in the
driver 's seat, the SRS driver 's air-
bag system will judge that the driv-
er wears the seat belt even if not
wearing it. In this case, the driver 's
airbag may not activate correctly,
causing death or serious injury in
the event of collision. Be sure to
wear the seat belt with the seat belt
extender.
ÐStowing the third seat seat
belt
ÐSeat belt extender

2005 HIGHLANDER (EWD592U)
83
2. Control System
*SFI system
The SFI system monitors the engine condition through the signals input from each sensor (Input signals from (1) to (12)
etc.) to the engine control module. And the control signal is output to TERMINALS #10, #20, #30, #40, #50 and #60 of
the engine control module to operate the injector (Inject the fuel). The SFI system controls the fuel injection operation by
the engine control module in response to the driving conditions.
*ESA system
The ESA system monitors the engine condition through the signals input to the engine control module from each sensor
(Input signals from (1) to (12) etc.). The best ignition timing is decided according to this data and the memorized data in
the engine control module and the control signal is output to TERMINALS IGT1, IGT2, IGT3, IGT4, IGT5 and IGT6. This
signal controls the igniter to provide the best ignition timing for the driving conditions.
*ACIS
The ACIS includes a valve in the bulkhead separating the surge tank into two parts. This valve is opened or closed
according to the driving conditions to control the intake manifold length in three stages, for increased engine output in all
ranges from low to high speeds, when idling.
3. Diagnosis System
With the diagnosis system, when there is a malfunction in the engine control module signal system, the malfunctioning
system is recorded in the memory. The malfunctioning system can be found by reading the code displayed by the
malfunction indicator lamp.
4. Fail-Safe System
When a malfunction has occurred in any system, if there is a possibility of engine trouble being caused by continued control
based on the signals from that system, the fail-safe system either controls the system by using data (Standard values)
recorded in the engine control module memory or else stops the engine.
CIRCUIT OPENING Relay
5-3 : Closed with the starter running
EFI Relay
5-3 : Closed with the ignition SW at ON or ST position
E5 (A), E6 (B), E7 (E), E8 (D), E9 (C) Engine Control Module
Voltage at engine control module wiring connector
BATT-E1 : Always 9.0-14.0 volts
VC-E2 : Always 4.5-5.5 volts (Ignition SW at ON position)
VG-E2G : 1.1-1.5 volts (Engine idling and A/C SW off)
THA-E2 : 0.5-3.4 volts (Engine idling and intake air temp. 20°C, 68°F)
THW-E2 : 0.2-1.0 volts (Engine idling and coolant temp. 80°C, 176°F)
IGF-E1 : 4.5-5.5 volts (Ignition SW at ON position)
Pulse generation (Engine idling)
SIL-E1 : Pulse generation (During transmission)
TACH-E1 : Pulse generation (Engine idling)
STA-E1 : 6.0 volts or more (Engine cranking)
FC-E1 : 9.0-14.0 volts (Ignition SW at ON position)
0-3.0 volts (Engine idling)
SPD-E1 : Pulse generation (Ignition SW on and rotate driving wheel slowly)
W-E1 : Below 3.0 volts (Ignition SW at ON position)
NSW-E1 : 9.0-14.0 volts (Ignition SW on and other shift position in P or N position)
0-3.0 volts (Ignition SW on and shift position in P or N position)
PRG-E01 : 9.0-14.0 volts (Ignition SW at ON position)
TC-E1 : 9.0-14.0 volts (Ignition SW at ON position)
STP-E1 : 7.5-14.0 volts (Ignition SW on and brake pedal depressed)
0-1.5 volts (Ignition SW on and brake pedal depressed)
PTNK-E1 : 3.0-3.6 volts (Ignition SW at ON position)
1.3-2.1 volts (Ignition SW on and apply vacuum 2.0 kpa)
OX1B, OX2B-E1 : Pulse generation (Maintain engine speed at 2500 rpm for two minutes after warming up)
KNK1, KNK2-E1 : Pulse generation (Engine idling)
IGT1, IGT2, IGT3, IGT4, IGT5, IGT6-E1 : Pulse generation (Engine idling)
#10, #20, #30, #40, #50, #60-E01 : 9.0-14.0 volts (ignition SW at ON position)
Pulse generation (Engine idling)
Service Hints

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Four- wheel drive models:
Do not use snow tires of different
brands, sizes, construction or tread
patterns, as this may cause danger-
ous handling characteristics result-
ing in loss of control.
SNOW TIRE INSTALLATION
Snow tires should be installed on all
wheels.
Installing snow tires on the front wheels
only can lead to an excessive difference
in road grip capability between the front
and rear tires, which could cause loss of
vehicle control.
When storing removed tires, you should
store them in a cool dry place.
Mark the direction of rotation and be sure
to install them in the same direction when
replacing.
CAUTION

Do not drive with the snow tires
incorrectly inflated.

Never drive over 120 km/h (75 mph)
with any type of snow tires.
Side chain
Cross chain
TIRE CHAIN SELECTION
Use the tire chains of correct size.
Use the following type chains.
mm (in.)
A Diameter of side chain 3 (0.12)
B Width of side chain 10 (0.39)
C Length of side chain 30 (1.18)
D Diameter of cross chain 4 (0.16)
E Width of cross chain 14 (0.55)
F Length of cross chain 25 (0.98)
Regulations regarding the use of tire
chains vary according to location or
type of road, so always check them
before installing chains.
NOTICE
If the wrong combination of tire and
chain is used, the chains could dam-
age the vehicle body.
CHAIN INSTALLATION
Install the chains on the front tires as
tightly as possible. Do not use tire
chains on the rear tires. Retighten
chains after driving 0.5Ð1.0 km
(1/4Ð1/2 mile).
When installing chains on your tires, care-
fully follow the instructions of the chain
manufacturer.
If wheel covers are used, they will be
scratched by the chain band, so remove
the covers before putting on the chains.

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2. Slide the cross rails to the appropri-
ate position for loading the luggages
and turn the side knobs clockwise to
tighten the cross rails securely.
Vehicles with the electric moon
roofÐThere are cross rail stoppers on the
roof rails which help you prevent the
cross rails being touched with the tilted up
moon roof.
NOTICE
Vehicles with the electric moon roof
onlyÐDo not remove the cross rail
stoppers, or the moon roof may be
damaged when it is tilted.
3. In order to fix the cross rails to the
appropriate length, turn the upper
knobs clockwise after tightening all
of the side knobs.
CAUTION
Make sure the cross rails are fixed
securely by pushing forward and rear-
ward them. Failure to do so may
cause an unexpected accident or se-
vere injury in the event of emergency
braking or a collision.
Follow the manufacture's instructions and
precautions when installing the attach-
ments or their equivalent.
CAUTION
When you load cargo on the roof lug-
gage carrier, observe the following:
Place the cargo so that its weight
is distributed evenly between the
front and rear axles.
If loading long or wide cargo, never
exceed the vehicle overall length or
width. (See Dimensions and
weightsº on page 406 in Section 8
for information on your vehicle
overall length and width.)
Before driving, make sure the cargo
is securely fastened on the roof
luggage carrier.
Loading cargo on the roof luggage
carrier will make the center of the
vehicle gravity higher. Avoid high
speeds, sudden starts, sharp turns,
sudden braking or abrupt maneu-
vers, otherwise it may result in loss
of control or vehicle rollover due to
failure to operate this vehicle cor-
rectly.

05EYX-02
F46772
Tire Pressure
Warning Reset Switch
Tire Pressure
Warning Lamp
Lamp Output Pattern:

Receipt of the Initialization Signal
Keep pressing
the switch for 3 sec.
1 Sec.

Failure of Initialization
0.25 Sec.
0.25 Sec. ON
OFF ON
OFF
1 Sec. 3 Sec. 05-736
- DIAGNOSTICSTIRE PRESSURE WARNING SYSTEM
926 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
INITIALIZATION
NOTICE:
This system requires initializing after changing tires or wheels, or after rotating the tires.
Be sure to adjust the tire air pressure to the specified value before initialization.
1. INITIALIZING THE TIRE PRESSURE WARNING SYS-
TEM
(a) Check and adjust the tire pressure to the specified value.
Specified Value
Front210 kpa (2.1 kgf/cm2, 30 psi)
Rear210 kpa (2.1 kgf/cm2, 30 psi)
(b) With the vehicle stopped, turn the ignition switch to the
ON position.
(c) Press and hold the tire pressure warning reset switch until
the tire pressure warning lamp blinks 3 times at 1 second
intervals.
HINT:
If the tire pressure warning lamp does not blink, perform the ini-
tialization again. (with the ignition switch off, perform the proce-
dure above starting at step 1-(b).)
(d) Drive the vehicle at 19 mph (30 km/h) or more, to com-
plete the initialization of the skid control ECU. (It takes
more than one hour.)
HINT:
If the tire pressure warning lamp blinks at 0.25 second intervals
while the vehicle is being driven, the initialization may have
failed. If so, perform the initialization again. (Turn the ignition
switch off and retry from step 1-(a).)
(e) After initialization is completed, the skid control ECU mon-
itors the tire pressure by using the wheel speed sensors.
(f) To verify the system has been initialized check the length
of time the tire pressure warning lamp is on after turning
the ignition switch to the ON position.
Not initialized: 4 sec.
Initialized: 3 sec.

05BYH-15
F45104
F45105
Bypass Wire
F45106
05-2090
- DIAGNOSTICSCAN COMMUNICATION SYSTEM
2280 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
CAN COMMUNICATION SYSTEM
PRECAUTION
1. HANDLING PRECAUTIONS ON STEERING SYSTEM
(a) Care must be taken when replacing parts. Incorrect replacement could affect the performance of the
steering system and result in a driving hazard.
2. HANDLING PRECAUTIONS ON SRS AIRBAG SYSTEM
(a) The HIGHLANDER is equipped with a SRS (Supplemental Restraint System), such as the driver air-
bag and front passenger airbag. Failure to carry out service operation in the correct sequence could
cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before
servicing (including removal or installation of parts, inspection or replacement), be sure to read the pre-
cautionary notice for the Supplemental Restraint System (see page 60-1).
3. WIRE HARNESS REPAIR
(a) After repairing the wire bus line with solder, wrap the re-
paired part with vinyl tape.
NOTICE:

The CANL bus line and CANH bus line must be
installed together all the time.
When installing, make sure to twist them.

The difference in length of the CANL bus line and
CANH bus line should be within 100 mm (3.937 in.).

Untwisted parts around the connectors should be
within 80 mm (3.150 in.).
(b) Do not perform bypass wiring between the connectors.
NOTICE:
If you perform bypass wiring, the characteristic of the
twisted wire harness will be lost.
4. CONNECTOR HANDLING
(a) When inserting tester probes into a connector, insert them
from the back of the connector.