Page 1449 of 2572
A90308
IG2I15
Ignition Switch
FC MRELECM
Y8
E5
6
7
4 Engine
Room J/B
AM2
FL
Main
Battery
EHW-B IGN
IC1
2F
E510 IA2 32 51
1
3
5
2
3 10
1AM2
EFI
NO. 1EFI
Relay
W
F12
Fuel Pump
BCBR
8 F7
FL Block AssyCircuit
Opening
Relay B
L L-Y
W
W-B
J2
J/C A Y
1 11 1
52B
12I82B
1IK3
2
IC213
B WWW
P-L GRInstrument Panel J/B AssyPassenger Side J/B
R/B No.1 4M4
4F1
1G6
1C1
54 05-350
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
540 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
WIRING DIAGRAM
Page 1450 of 2572

B60778
5
12 312
5
3
A67446
FC (+)E1 (-)
E9
ECME5
ECM
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-351
541 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
INSPECTION PROCEDURE
Hand-held tester:
1 PERFORM ACTIVE TEST USING HAND-HELD TESTER (OPERATE CIRCUIT
OPENING RELAY)
(a) Connect the hand-held tester to the DLC3.
(b) Turn ON the ignition switch. Push the hand-held tester main switch.
(c) Enter the following menus: DIAGNOSIS / ENHANCED OBD II / ACTIVE TEST / FUEL PUMP / SPD.
(d) Check the relay operation while operating it with the hand-held tester.
OK: Operating noise can be heard from the relay.
OK Go to step 5
NG
2 INSPECT CIRCUIT OPENING RELAY
(a) Remove the circuit opening relay from the R/B sub-assy.
(b) Measure the resistance of the circuit opening relay.
Standard:
Tester ConnectionSpecified Condition
3 - 510 kW or higher
3 - 5Below 1 W
(when battery voltage is applied to terminals 1 and 2)
NG REPLACE CIRCUIT OPENING RELAY
OK
3 INSPECT ECM (FC VOLTAGE)
(a) Turn the ignition switch ON.
(b) Measure the voltage of the ECM connectors.
Standard:
Tester ConnectionSpecified Condition
E5-10 (FC) - E9-1 (E1)9 to 14 V
OK REPLACE ECM (See page 10-9)
NG
Page 1451 of 2572

A67445
A90342
A92641
E5
ECM
FC
Circuit Opening
Relay
R/B Sub-assy
1234
5678
A90342
A90344
A61075
A92642
Wire Harness Side
Instrument
Panel J/B
Assy
IGN fuse
I15
Ignition Switch
IG2R/B Sub-assy
Circuit Opening
Relay
05-352
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
542 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
4 CHECK WIRE HARNESS (ECM - CIRCUIT OPENING RELAY, CIRCUIT OPENING
RELAY - IGNITION SWITCH)
(a) Check the wire harness between the ECM and circuit
opening relay.
(1) Disconnect the E5 ECM connector.
(2) Remove the circuit opening relay from the R/B sub-
assy.
(3) Measure the resistance of the wire harness side
connectors.
Standard:
Tester ConnectionSpecified Condition
E5-10 (FC) - R/B sub-assy circuit opening relay terminal 2Below 1 W
E5-10 (FC) or
R/B sub-assy circuit opening relay terminal 2 - Body ground10 kW or higher
(b) Check the wire harness between the circuit opening relay
and ignition switch.
(1) Check the IGN fuse.
Remove the IGN fuse from the instrument
panel J/B.
Measure the resistance of the IGN fuse.
Standard: Below 1 W
Reinstall the IGN fuse.
(2) Remove the circuit opening relay from the R/B sub-
assy.
(3) Disconnect the I15 ignition switch connector.
(4) Measure the resistance of the wire harness side
connectors.
Standard:
Tester ConnectionSpecified Condition
R/B sub-assy circuit opening relay terminal 1 - I15-6 (IG2)Below 1 W
I15-6 (IG2) or
R/B sub-assy circuit opening relay terminal 1 - Body ground10 kW or higher
NG REPAIR OR REPLACE HARNESS AND
CONNECTOR
OK
Page 1452 of 2572

1 2 3
54
A74356
F12
Fuel Pump
A90342
A67586A92648
Circuit Opening Relay Wire Harness Side
F12
Fuel Pump
R/B Sub-assy
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-353
543 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
REPLACE ECM (See page 10-9)
5 INSPECT FUEL PUMP ASSY
(a) Measure the resistance of the fuel pump terminals.
Standard:
Tester ConditionConditionSpecified Condition
4 - 520C (68F)0.2 to 0.3 W
(b) Check operation of the fuel pump.
(1) Apply battery voltage to both the terminals. Check
that the pump operates.
NOTICE:
These tests must be done quickly (within 10 seconds)
to prevent the coil from burning out.
Keep the fuel pump as far away from the battery as
possible.
Always turn ON and OFF the voltage on the battery
side, not the fuel pump side.
NG REPLACE FUEL PUMP ASSY
(See page 11-16)
OK
6 CHECK WIRE HARNESS (CIRCUIT OPENING RELAY - FUEL PUMP, FUEL PUMP -
BODY GROUND)
(a) Check the wire harness between the circuit opening relay
and fuel pump.
(1) Remove the circuit opening relay from the R/B sub-
assy.
(2) Disconnect the F12 fuel pump connector.
(3) Measure the resistance of the wire harness side
connectors.
Standard:
Tester ConnectionSpecified Condition
R/B sub-assy circuit opening relay terminal 3 - F12-4Below 1 W
F12-4 or
R/B sub-assy circuit opening relay terminal 3 - Body ground10 kW or higher
Page 1453 of 2572

A67586
F12
Fuel Pump Wire Harness Side
A53765
E5
ECM
FC
05-354
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
544 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(b) Check the wire harness between the fuel pump and body
ground.
(1) Disconnect the F12 fuel pump connector.
(2) Measure the resistance between the wire harness
side connector and body ground.
Standard:
Tester ConnectionSpecified Condition
F12-5 - Body groundBelow 1 W
OK REPAIR OR REPLACE HARNESS AND
CONNECTOR
NG
REPLACE ECM (See page 10-9)
OBD II scan tool (excluding hand-held tester):
1 CHECK FUEL PUMP OPERATION (See Page 11-4)
(a) Check if there is pressure in the fuel inlet hose.
HINT:
The pipe has fuel pressure if the sound of flowing fuel can be heard.
OK PROCEED TO NEXT CIRCUIT INSPECTION
SHOWN ON PROBLEM SYMPTOMS TABLE
(See page 05-31)
NG
2 CHECK RELAY OPERATION (CIRCUIT OPENING RELAY)
(a) When connecting between terminal FC of the ECM con-
nector and body ground, check relay operation.
OK: Noise can be heard from the circuit opening
relay.
OK Go to step 6
NG
Page 1454 of 2572
B60778
5
12312
5
3
A67446
FC (+)E1 (-)
E9
ECME5
ECM
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-355
545 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
3 INSPECT CIRCUIT OPENING RELAY
(a) Remove the circuit opening relay from the R/B sub-assy.
(b) Measure the resistance of the circuit opening relay.
Standard:
Tester ConnectionSpecified Condition
3 - 510 kW or higher
3 - 5Below 1 W
(when battery voltage is applied to terminals 1 and 2)
NG REPLACE CIRCUIT OPENING RELAY
OK
4 INSPECT ECM (FC VOLTAGE)
(a) Turn the ignition switch ON.
(b) Measure the voltage of the ECM connectors.
Standard:
Tester ConnectionSpecified Condition
E5-10 (FC) - E9-1 (E1)9 to 14 V
OK REPLACE ECM (See page 10-9)
NG
Page 1455 of 2572

A67445
A90342
A92641
E5
ECM
FC
R/B Sub-assy
Circuit Opening
Relay
1234
5678
A90342
A90344
A61075
A92642
Wire Harness Side
Instrument
Panel J/B
Assy
IGN fuse
I15
Ignition Switch
IG2R/B Sub-assy
Circuit Opening
Relay
05-356
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
546 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
5 CHECK WIRE HARNESS (ECM - CIRCUIT OPENING RELAY, CIRCUIT OPENING
RELAY - IGNITION SWITCH)
(a) Check the wire harness between the ECM and circuit
opening relay.
(1) Disconnect the E5 ECM connector.
(2) Remove the circuit opening relay from the R/B sub-
assy.
(3) Measure the resistance of the wire harness side
connectors.
Standard:
Tester ConnectionSpecified Condition
E5-10 (FC) - R/B sub-assy circuit opening relay terminal 2Below 1 W
E5-10 (FC) or
R/B sub-assy circuit opening relay terminal 2 - Body ground10 kW or higher
(b) Check the wire harness between the circuit opening relay
and ignition switch.
(1) Check the IGN fuse.
Remove the IGN fuse from the instrument
panel J/B Assy.
Check the resistance of the IGN fuse.
Standard: Below 1 W
Reinstall the IGN fuse.
(2) Remove the circuit opening relay from the R/B sub-
assy.
(3) Disconnect the I15 ignition switch connector.
(4) Measure the resistance of the wire harness side
connectors.
Standard:
Tester ConnectionSpecified Condition
R/B sub-assy circuit opening relay terminal 1 - I15-6 (IG2)Below 1 W
I15-6 (IG2) or
R/B sub-assy circuit opening relay terminal 1 - Body ground10 kW or higher
NG REPAIR OR REPLACE HARNESS AND
CONNECTOR
OK
Page 1456 of 2572

1 2 3
54
A74356
F12
Fuel Pump
A90342
A67586A92648
Wire Harness Side
F12
Fuel Pump
R/B Sub-assy
Circuit Opening Relay
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-357
547 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
REPLACE ECM (See page 10-9)
6 INSPECT FUEL PUMP ASSY
(a) Measure the resistance of the fuel pump terminals.
Standard:
Tester ConditionConditionSpecified Condition
4 - 520C (68F)0.2 to 0.3 W
(b) Check operation of the fuel pump.
(1) Apply battery voltage to both the terminals. Check
that the pump operates.
NOTICE:
These tests must be done quickly (within 10 seconds)
to prevent the coil from burning out.
Keep the fuel pump as far away from the battery as
possible.
Always turns ON and OFF the voltage on the battery
side, not the fuel pump side.
NG REPLACE FUEL PUMP ASSY
(See page 11-16)
OK
7 CHECK WIRE HARNESS (CIRCUIT OPENING RELAY - FUEL PUMP, FUEL PUMP -
BODY GROUND)
(a) Check the wire harness between the circuit opening relay
and fuel pump.
(1) Remove the circuit opening relay from the R/B Sub-
Assy.
(2) Disconnect the F12 fuel pump connector.
(3) Measure the resistance of the wire harness side
connectors.
Standard:
Tester ConnectionSpecified Condition
R/B sub-assy circuit opening relay terminal 3 - F12-4Below 1 W
F12-4 or
R/B sub-assy circuit opening relay terminal 3 - Body ground10 kW or higher