2001 TOYOTA HIGHLANDER change time

9900X-21
99-4
- MAINTENANCEUNDER HOOD
3784 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
UNDER HOOD
GENERAL MAINTENANCE
1. GENERAL NOTES

Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.

Every service item in the periodic maintenance schedule must be performed.

Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

Maintenance service after the last period should be performed at the same interval as before unless
noted.

Failure to do even one of the items can cause the engine to run poorly and/or increase the exhaust
emissions.
2. WINDSHIELD WASHER FLUID
(a) Check that there is sufficient fluid in the tank.
3. ENGINE COOLANT LEVEL
(a) Check that the coolant level is between the LEVEL lines on the see-through reservoir at normal tem-
perature (20°C (68°F)).
4. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not blocked by leaves, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or loose connections.
5. BATTERY ELECTROLYTE LEVEL
(a) Check the indicator.
(b) Check that the electrolyte level of all the battery cells is between the upper and lower level lines on
the case.
6. BRAKE FLUID LEVEL
(a) Check that the brake fluid levels are near the upper level line on the see-through reservoirs.
7. ENGINE DRIVE BELT
(a) Check the drive belt for fraying, cracks, wear or oiliness.
8. ENGINE OIL LEVEL
(a) Check the level on the dipstick with the engine turned off.
9. POWER STEERING FLUID LEVEL
(a) Check the level on the dipstick.
(b) The level should be in the ºHOTº or ºCOLDº range depending on the fluid temperature.
10. AUTOMATIC TRANSMISSION FLUID LEVEL
(a) Park the vehicle on a level surface.
(b) With the engine idling and the parking brake applied, shift the selector into all the positions from ºPº
to ºLº, and then shift into the ºPº position.
(c) Pull out the dipstick and wipe off the fluid with a clean shop rag. Re-insert the dipstick and check that
the fluid level is in the ºHOTº range.
(d) Perform this check with the fluid at the normal driving temperature (70 to 80°C, 158 to 176°F).
HINT:
Wait until the engine cools down (approx. 30 min.) before checking the fluid level after extended driving at
high speed, in hot weather, in heavy traffic or after pulling a trailer.
11. EXHAUST SYSTEM
(a) Visually inspect for cracks, holes or loose supports.
If any change in the sound of the exhaust or the smell of the exhaust fumes is noticed, locate and correct
the cause.

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2005 HIGHLANDER (EWD592U)
6
B HOW TO USE THIS MANUAL
Current is applied at all times through the STOP fuse to TERMINAL 2 of the stop light SW.
When the ignition SW is turned on, current flows from the GAUGE fuse to TERMINAL 8 of the light failure sensor, and also flows
through the rear lights warning light to TERMINAL 4 of the light failure sensor.
Stop Light Disconnection Warning
When the ignition SW is turned on and the brake pedal is pressed (Stop light SW on), if the stop light circuit is open, the current
flowing from TERMINAL 7 of the light failure sensor to TERMINALS 1, 2 changes, so the light failure sensor detects the
disconnection and the warning circuit of the light failure sensor is activated.
As a result, the current flows from TERMINAL 4 of the light failure sensor to TERMINAL 11 to GROUND and turns the rear lights
warning light on. By pressing the brake pedal, the current flowing to TERMINAL 8 of the light failure sensor keeps the warning
circuit on and holds the warning light on until the ignition SW is turned off.
S6 Stop Light SW
2-1 : Closed with the brake pedal depressed
L4 Light Failure Sensor
1, 2, 7-Ground : Approx. 12 volts with the stop light SW on
4, 8-Ground : Approx. 12 volts with the ignition SW at ON position
11-Ground : Always continuity
: Parts Location
CodeSee PageCodeSee PageCodeSee Page
C734L436R737
H1736R637S635
: Relay Blocks
CodeSee PageRelay Blocks (Relay Block Location)
118R/B No.1 (Instrument Panel Brace LH)
: Junction Block and Wire Harness Connector
CodeSee PageJunction Block and Wire Harness (Connector Location)
IB20Instrument Panel Wire and Instrument Panel J/B (Lower Finish Panel)
3C22Instrument Panel Wire and J/B No.3 (Instrument Panel Brace LH)
: Connector Joining Wire Harness and Wire Harness
CodeSee PageJoining Wire Harness and Wire Harness (Connector Location)
IE142Floor Wire and Instrument Panel Wire (Left Kick Panel)
BV150Luggage Room Wire and Floor Wire (Luggage Room Left)
: Ground Points
CodeSee PageGround Points Location
BL50Under the Left Center Pillar
BO50Back Panel Center
: Splice Points
CodeSee PageWire Harness with Splice PointsCodeSee PageWire Harness with Splice Points
I544Cowl WireB1850Luggage Room Wire
System Outline
Service Hints

i
2005 HIGHLANDER Navigation from Aug. '04 Prod. (OM48539U)
Introduction
Thank you for your purchase of the Navigation System. Please read this manual carefully to ensure proper use. Keep this manual
in your vehicle at all times.
The Navigation System is one of the most technologically advanced vehicle accessories ever developed. The system receives satellite signals
from the Global Positioning System (GPS) operated by the U.S. Department of Defense. Using these signals and other vehicle sensors, the
system indicates your present position and assists in locating a desired destination.
The navigation system is designed to select efficient routes from your present starting location to your destination. The system is designed
to direct you to a destination that is unfamiliar to you in an efficient manner. The system uses the maps of DENSO. The calculated routes
may not be the shortest nor the least traffic congested. Your own personal local knowledge or short cutº may at times be faster than the calcu-
lated routes.
The navigation system's database includes about 75 Point of Interest categories to allow you to easily select destinations such as restaurants
and banks. If a destination is not in the database, you can enter the street address or a major intersection close to it and the system will guide
you there. The system will provide both a visual map and audio instructions. The audio instructions will announce the distance remaining
and the direction to turn in approaching a fork or intersection. These voice instructions will help you keep your eyes on the road and are timed
to provide enough time to allow you to maneuver, change lanes or slow down.
Please be aware that all current vehicle navigation systems have certain limitations that may affect their ability to perform properly.
The accuracy of the vehicle's position depends on the satellite condition, road configuration, vehicle condition or other circumstan-
ces. For more information on the limitations of the system, refer to pages 9 through 11.

INTRODUCTIONIN-16
PRECAUTIONS FOR REPAIRING BODY
STRUCTURE PANELS
1. HEAT REPAIR FOR BODY STRUCTURE
PANELS
Toyota prohibits the use of the heat repair method on body
structure panels when repairing a vehicle damaged in a col-
lision.
Panels that have high strength and rigidity, as well as a long
life span for the automobile body are being sought after.
At Toyota, in order to fulfill these requirement, we use high
tensile strength steel sheets and rust preventive steel
sheets on the body.
High tensile steel sheets are made with alloy additives and
a special heat treatment in order to improve the strength.
To prevent the occurrence of rust for a long period of time,
the surface of the steel is coated with a zinc alloy.
If a body structure parts are heat repaired with an acetylene
torch or other heating source, the crystalline organization of
the steel sheet will change and the strength of the steel
sheet will be reduced.
The ability of the body to resist rust is significantly lowered
as well since the rust resistant zinc coating is destroyed by
heat and the steel sheet surface is oxidized.
2. STRUCTURE PANEL KINKS
A sharp deformation angle on the panel that cannot be re-
turned to its original shape by pulling or hammering is
called a kink.
Since structure parts were designed to exhibit a 100% per-
formance when they were in their original shape, if they are
deformed in an accident, or if the deformed parts are re-
paired and reused, they become unable to exhibit the same
performance as intended in the design.
It is necessary to replace the part where the kink has oc-
curred.

- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-771
961 Author
: Date
: ItemDiagnostic Note Vehicle Condition / Test Details
BRAKE WRN LIGHTTurns BRAKE warning light ON / OFFObserve combination me-
ter
VSC / BR WARN BUZTurns VSC / BRAKE warning buzzer ON / OFFBuzzer can be heard
*: 2WD only
6. FREEZE FRAME DATA
HINT:

Whenever a DTC is detected or the ABS operates, the skid control ECU stores the current vehicle (sen-
sor) state as freeze frame data.

The skid control ECU stores the number of times (maximum: 31) the ignition switch has been turned
from off to the On position since the last time ABS was activated. However, if the vehicle was stopped
or at low speed (4.3 mph (7 km/h) or less), or if a DTC is detected, the skid control ECU will not count
the number since then.

Freeze frame data at the time the ABS operates:
The skid control ECU stores and updates data whenever the ABS system operates.
When the ECU stores data at the time a DTC is detected, the data stored when the ABS operated is
erased.

Freeze frame data at the time a DTC is detected:
When the skid control ECU stores data at the time a DTC is detected, no updates will be performed
until the data is cleared.
(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 ºFREEZE FRAME DATAº.
Hand-held tester displayMeasurement ItemReference Value
VEHICLE SPDWheel speed sensor readingSpeed indicated on speedometer
STOP LIGHT SWStop lamp switch signalStop lamp switch ON: ON, OFF: OFF
# IG ONNumber of operations of ignition switch ON after
memorizing freeze frame data0 to 31
MAS CYL PRESSMaster cylinder pressure sensor readingBrake pedal release : 0.3 to 0.9 V
Brake pedal depress: 0.8 to 4.5 V
MASS PRESS GRADEMaster cylinder pressure sensor change-30 to 200 MPa/s
SYSTEMSystem status
ABS activated: ABS
VSC/TRC activated: VSC/TRC
BA activated: BA
Fail safe mode activated: FAIL SF
No system activated: NO SYS
YAW R AT EYaw rate angle sensor reading-100 to 100
STEERING ANGSteering sensor readingLeft turn: Increase
Right turn: Decrease
G (RIGHT & LEFT)Right and left G-1.869 to 1.869
G (BACK & FORTH)Back and forth G-1.869 to 1.869
VSC (TRC) OFF SW*TRAC control switch signalTRC control switch ON: ON
OFF: OFF
SHIFT POSITIONShift lever position
FAIL
P, N
R
D
4
3
2
L
THROTTLEThrottle sensor reading0 to 125 deg.
*: 2WD only

I30328
w/o Navigation System
I38758
w/ Navigation System
I30337
ECU-B Fuse Engine Room J/B
F46779
- DIAGNOSTICSAIR CONDITIONING SYSTEM
05-1 119
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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.

I30329
w/o Navigation System
I38758
w/ Navigation System
Blower level Step No.Display
codeConditions
Air flow vent
Air inlet damper Magnetic clutch
ºCOOLº side
(Fully closed) Air mix damper
OFF FRESH FACE 0 1
2
3
4
6
7
8
9
10 4
51
17
17
17
17
17
17
17
31 0
1
2
3
6
7
8 4
5
9FACE
FACE
FACE
FACE
B/L
FOOT
FOOT
FOOT/ DEF
DEFFRESH
RECIRCULATION
RECIRCULATION
RECIRCULATION
RECIRCULATION
RECIRCULATION
RECIRCULATIONOFF
ON
ON
ON
ON
ON
ON
ON
ONºCOOLº side
(Fully closed)
ºCOOLº side
(Fully closed)
ºCOOLº side
(Fully closed)
ºCOOLº/ ºWARM º
(50% open)
ºCOOLº/ ºWARM º
(50% open)
ºWARMº side
(Fully opened)
ºWARMº side
(Fully opened)
ºWARMº side
(Fully opened) FRESH
FRESH
ºWARMº side
(Fully opened)
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2005 HIGHLANDER REPAIR MANUAL (RM1144U)
6. ACTUATOR CHECK
(a) Turn the ignition switch to the ON position while pressing
the A/C control AUTO switch and R/F (Recirculation /
Fresh) switch simultaneously.
(b) As each damper, motor and relay automatically operate
the actuator check at 1 second intervals from step No.1
to No.10 continuously, check the temperature and air flow
visually and by hand.
If a slower display is desired, press the temperature up switch
and change the display in the step operation. Each time the
temperature up switch is pressed, the display changes by 1
step.
HINT:

Codes are displayed from the smaller to the larger num-
bers in order.

To cancel the check mode, press the ºOFFº switch.

3 2 1 45678
9 1 0 111 21 31 41 51 6
DLC3
A04550
- DIAGNOSTICSAIR CONDITIONING SYSTEM
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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)-