water pump TOYOTA HIGHLANDER 2001 Service Repair Manual

'05 HIGHLANDER_U (L/O 0409)
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2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
Look at the see- through coolant reser-
voir when the engine is cold. The cool-
ant level is satisfactory if it is between
the Fº and Lº lines on the reservoir.
If the level is low, add the coolant. (For
the coolant type, see Coolant type
selectionº described below.)
The coolant level in the reservoir will vary
with engine temperature. However, if the
level is on or below the Lº line, add
coolant. Bring the level up to the Fº line.
If the coolant level drops within a short
time after replenishing, there may be a
leak in the system. Visually check the
radiator, hoses, radiator cap and drain
cock and water pump.
If you can find no leak, have your Toyota
dealer test the cap pressure and check
for leaks in the cooling system.
CAUTION
To prevent burning yourself, do not
remove the radiator cap when the en-
gine is hot.
Coolant type selection
Use of improper coolants may damage
your engine cooling system.
Only use Toyota Super Long Life Coolantº
or similar high quality ethylene glycol
based non- silicate, non- amine, non- nitrite,
and non- borate coolant with long- life
hybrid organic acid technology. (Coolant
with long- life hybrid organic acid
technology is a combination of low
phosphates and organic acids.)
For the U.S.A.ÐToyota Super Long Life
Coolantº is a mixture of 50% coolant and
50% deionized water. This coolant pro-
vides protection down to about -35C
(- 31F).
For CanadaÐToyota Super Long Life
Coolantº is a mixture of 55% coolant and
45% deionized water. This coolant pro-
vides protection down to about -42C
(- 44F).
NOTICE
Do not use plain water alone.
Toyota recommends Toyota Super Long
Life Coolantº, which has been tested to
ensure that it will not cause corrosion nor
result in malfunction of your engine
coolant system with proper usage. Toyota
Super Long Life Coolantº is formulated
with long- life hybrid organic acid
technology and has been specifically
designed to avoid engine cooling system
malfunction on Toyota vehicles.
Please contact your Toyota dealer for
further details.
Checking the engine coolant
level

'05 HIGHLANDER_U (L/O 0409)
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2005 HIGHLANDER from Nov. '04 Prod. (OM48570U)
5. After completing the tire inflation
pressure measurement and ad-
justment, apply soapy water to the
valve and check for leakage.
6. Install the tire valve cap.
If a gauge and air pump are not avail-
able, have your vehicle checked by
your Toyota dealer.
CAUTION
Be sure to reinstall the tire valve
caps. Without the valve caps, dirt
or moisture could get into the
valve core and cause air leakage.
If the caps have been lost, have
new ones put on as soon as pos-
sible.
Incorrect tire inflation pressure may
waste fuel, reduce the comfort of driv-
ing, reduce tire life and make your ve-
hicle less safe to drive.
If a tire frequently needs refilling,
have it checked by your Toyota deal-
er.
CAUTION
Keep your tires properly inflated.
Otherwise, the following condi-
tions may occur and cause an ac-
cident resulting in death or seri-
ous injuries.
Low tire pressure (underinfla-
tion)Ð

Excessive wear

Uneven wear

Poor handling

Possibility of blowouts from an
overheated tire

Poor sealing of the tire bead

Wheel deformation and/or tire
separation

A greater possibility of tire
damage from road hazards
High tire pressure (overinfla-
tion)Ð

Poor handling

Excessive wear

Uneven wear

A greater possibility of tire
damage from road hazards

A85255
Pressure Gauge
Pressure
B06546
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
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28 REPLACE FUEL TANK CAP ASSY
HINT:
When installing the fuel tank cap, tighten it until a few click sounds are heard.
NEXT Go to step 37
29 REPAIR EVAP LEAK PART
(a) Reinstall the fuel cap.
(b) Remove the exhaust tail pipe.
(c) Remove the heat insulator under the canister.
(d) Pinch the atmospheric side hose of the pump module with
the clip to close the canister's passage to air.
(e) Connect the pressure gauge (SST) to the service port
(green cap near the air cleaner box).
(f) Pressurize the EVAP system to 3.2 to 3.7 kPa (24 to 28
mmHg).
NOTICE:
More than 35 mmHg of pressure will damage the EVAP sys-
tem. Pay attention to the pressure.
(g) Apply soapy water to the piping and connecting parts of
the EVAP system. Look for the area where bubbles ap-
pear. This area cause leaks.
HINT:

If the system has leaks, a whistling sound will be heard.

Disconnect the hose between canister and fuel tank from
the canister. Close the canister on the area where the
hose was connected and perform an inspection. The fuel
tank can be eliminated from the suspected areas for leak
checks.
(h) Repair or replace the leak point.
NEXT Go to step 37
30 REPLACE CHARCOAL CANISTER ASSY
NEXT Go to step 37

05-1674
- DIAGNOSTICSAUDIO SYSTEM
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NOISE OCCURS
INSPECTION PROCEDURE
1 CHECK OF SPEAKER INSTALLATION
(a) Check the speaker installation condition.
(1) Check that each speaker is securely installed.
OK: Malfunction disappears.
HINT:
The radio is equipped with a noise prevention system that blocks only excessively loud noise. If loud noise
occurs, check whether or not the ground on the antenna installation part and the proper noise-prevention
equipment are all installed, and whether or not there is improper wiring.
Condition in which noise occursNoise type
Depressing the acceleration pedal increases the noise, and stopping the
engine stops the noise immediately.Alternator noise
Noise occurs during A/C or the heater operation.Blower motor noise
Rapid acceleration during the drive on an unpaved road or after the ignition
switch is turned on makes noise.Fuel pump noise
Pressing and then releasing the horn switch, and keeping pressing the horn
switch makes noise.Horn noise
Quiet noise is heard while the engine is running, but stops with the engine.Ignition noise
Noise occurs in turn with the blink of the turn signal flash.Flasher noise
Noise occurs during window washer operation.Washer noise
Noise occurs while the engine is running, and it continues even after the en-
gine is stopped.Water temperature sensor noise
Noise occurs during wiper operation.Wiper noise
Noise occurs when the brake pedal is depressed.Stop light switch noise
OthersStatic electricity on the vehicle
HINT:

Identify the condition in which the noise occurs, and check the noise filter on the related part.

Make sure first that there is no noise from outside. Failing to do so makes the noise occurrence source
detection difficult and leads to misdiagnosis.

The noise should be removed in descending order of loudness.
NG INSTALL IT PROPERLY
OK
IDENTIFICATION OF NOISE SOURCE
055M1-10

010QP-01
01-46
- INTRODUCTIONTERMS
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GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )--ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal-
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection-
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position-
CTOXContinuous Trap Oxidizer-
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel InjectionDirect Injection (DI/INJ)
DIDistributor Ignition-
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Communication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Trouble Code
DTMDiagnostic Test Mode-
ECLEngine Coolant Level-
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionDistributorless Ignition (DLI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control-
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory-
FEPROMFlash Erasable Programmable Read Only Memory-
FFFlexible Fuel-
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)

SST
A36684
SST
A36685
A13325
SST
A36335
Bracket
A53037
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- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
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(c) Remove the crankshaft pulley.
(1) Using SST, fix the pulley and loosen the bolt.
SST 09213-54015 (91651-60855), 09330-00021
(2) Using SST, remove the bolt and pulley.
SST 09950- 50013 (09951- 05010, 09952- 05010,
09953-05020, 09954-05021)
10. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts, chain tensioner and gasket.
NOTICE:
Do not turn the crankshaft without the chain tensioner.
11. REMOVE WATER PUMP PULLEY
(a) Using SST, remove the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
12. REMOVE WATER PUMP ASSY
(a) Remove the 4 bolts, 2 nuts, bracket and water pump.

A94202
Seal PackingSeal Width:
3.0 to 4.0 mm6.0 mm
(0.236 in.)
A64641
110 911
12
13
14 8
7
6
5
432
A94203
Seal Width:
2.2 to 2.5 mm
0.5 to 1.0 mm
(0.020 to 0.039 in.)
14-64
- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
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80. INSTALL OIL PAN SUB-ASSY
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not start the engine for at least 2 hours after instal-
ling.
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the cylinder
block and oil pan.
(b) Apply seal packing in a continuous bead (seal width: 3.0
to 4.0 mm (0.12 to 0.16 in.)) as shown in the illustration,
and install the oil pan.
Seal packing: Part No. 08826-00080 or equivalent
(c) Uniformly tighten the 12 bolts and 2 nuts in the sequence
shown in the illustration.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
81. INSTALL OIL PAN DRAIN PLUG
(a) Install a new gasket and the drain plug.
Torque: 25 NVm (255 kgfVcm, 18 ftVlbf)
82. INSTALL WATER PUMP ASSY
(a) Clean the contact surface of the cylinder block.
(b) Apply seal packing in a continuous bead (seal width: 2.2
to 2.5 mm (0.087 to 0.098 in.)) to the outside edge of the
water pump.
Seal packing: Part No. 08826-00100 or equivalent
NOTICE:

Remove any oil from the contact surface.

Install the water pump within 5 minutes after applying
seal packing.

Do not start the engine for at least 2 hours after instal-
ling.

B12052
SST
A36335
Rib
Wire Harness
Clamp
A52071
SST
A36684
Raise
PinHook
Push
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- ENGINE MECHANICALPARTIAL ENGINE ASSY (2AZ-FE)
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(c) Install the water pump with the 4 bolts and 2 nuts.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
NOTICE:
Tighten the outside bolts and nuts with the clamp.
83. INSTALL WATER PUMP PULLEY
(a) Using SST, install the water pump pulley with the 4 bolts.
SST 09960-10010 (09962-01000, 09963-00700)
Torque: 26 NVm (265 kgfVcm, 19 ftVlbf)
84. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the sensor with the 2 bolts.
Torque: 9.0 NVm (92 kgfVcm, 80 in.Vlbf)
(b) Confirm that the wire harness of the sensor is placed as
shown in the illustration.
85. INSTALL CRANKSHAFT PULLEY
(a) Install the pulley.
(b) Using SST,tighten the bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 180 NVm (1,835 kgfVcm, 133 ftVlbf)
HINT:
Apply a light coat of engine oil to the bolt threads and the area
beneath the bolt head that come in contact with the washer.
86. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Release the ratchet pawl, fully push in the plunger and ap-
ply the hook to the pin so that the plunger cannot spring
out.