Page 2105 of 2572

05-52
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
242 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)P0505
(05-226)
Idle Control System
Electronic throttle control system
Air induction system
PCV hose connection
ECM
P0560
(05-229)System VoltageOpen in back-up power source circuit
ECM
P0604
(05-233)Internal Control Module Random
Access Memory (RAM) ErrorECM
P0606
(05-233)ECM/PCM ProcessorSame as DTC No. P0604
P0607
(05-233)Control Module PerformanceSame as DTC No. P0604
P0617
(05-235)Starter Relay Circuit High
Short in PNP switch
PNP switch
Ignition switch
ECM
P0630
(05-241)VIN not Programmed or Mis-
match - ECM/PCMECM
P0657
(05-233)Actuator Supply Voltage Circuit /
OpenSame as DTC No. P0604
P0705
(05-242)Transmission Range Sensor Cir-
cuit Malfunction (PRNDL Input)Short in PNP switch circuit
PNP switch
ECM
P0710
(05-928)Transmission Fluid Temperature
Sensor ºAº circuitElectronic controlled automatic transmission (ECT)
P0711
(05-933)Transmission Fluid Temperature
Sensor ºAº PerformanceElectronic controlled automatic transmission (ECT)
P0712
(05-928)Transmission Fluid Temperature
Sensor ºAº Circuit Low InputElectronic controlled automatic transmission (ECT)
P0713
(05-928)Transmission Fluid Temperature
Sensor ºAº Circuit High InputElectronic controlled automatic transmission (ECT)
P0717
(05-937)Input/Turbine Speed Sensor ºAº
Circuit No SignalElectronic controlled automatic transmission (ECT)
P0724
(05-940)Brake Switch ºBº Circuit HighElectronic controlled automatic transmission (ECT)
P0741
(05-944)Torque Converter Clutch Circuit
Performance or Stuck OffElectronic controlled automatic transmission (ECT)
P0746
(05-949)Pressure Control Solenoid ºAº
Performance (Shift Solenoid
Valve SL1)
Electronic controlled automatic transmission (ECT)
P0748
(05-953)Pressure Control Solenoid ºAº
Electrical (Shift Solenoid Valve
SL1)
Electronic controlled automatic transmission (ECT)
P0766
(05-949)Shift Solenoid ºDº Performance
(Shift Solenoid Valve S4)Electronic controlled automatic transmission (ECT)
P0776
(05-949)Pressure Control Solenoid ºBº
Performance (Shift Solenoid
Valve SL2)
Electronic controlled automatic transmission (ECT)
P0778
(05-953)Pressure Control Solenoid ºBº
Electrical (Shift Solenoid Valve
SL2)
Electronic controlled automatic transmission (ECT)
P0793
(05-967)Intermediate Shaft Speed Sensor
ºAº Circuit No SignalElectronic controlled automatic transmission (ECT)
P0982
(05-953)Shift Solenoid ºDº Control LowElectronic controlled automatic transmission (ECT)
P0983
(05-953)Shift Solenoid ºDº Control HighElectronic controlled automatic transmission (ECT)
Page 2106 of 2572

- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-53
243 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)P2102
(05-243)
Throttle Actuator Control Motor
Circuit LowOpen in throttle actuator circuit
Throttle actuator
ECM
P2103
(05-243)Throttle Actuator Control Motor
Circuit High
Short in throttle actuator circuit
Throttle actuator
Throttle valve
Throttle body assy
ECM
P2111
(05-247)Throttle Actuator Control System
- Stuck Open
Throttle actuator circuit
Throttle actuator
Throttle body
Throttle valve
P2112
(05-247)Throttle Actuator Control System
- Stuck ClosedSame as DTC No. P2111
P2118
(05-250)Actuator Control Motor Current
Range/PerformanceOpen in ETCS power source circuit
ECM
P2119
(05-255)Throttle Actuator Control Throttle
Body Range/PerformanceElectronic throttle control system
ECM
P2120
(05-257)Throttle/Pedal Position Sensor/
Switch ºDº Circuit
Accelerator pedal position sensor
Open in VCP1 circuit
VPA circuit open or ground short
ECM
P2121
(05-265)Throttle/Pedal Position Sensor/
Switch ºDº Circuit Range/Perfor-
manceOpen or short in Accelerator pedal position sensor circuit
Accelerator pedal position sensor
ECM
P2122
(05-257)Throttle/Pedal Position Sensor/
Switch ºDº Circuit Low Input
Accelerator pedal position sensor
Open in VCP1 circuit
VPA circuit open or ground short
ECM
P2123
(05-257)Throttle/Pedal Position Sensor/
Switch ºDº Circuit High InputAccelerator pedal position sensor
Open in EPA circuit
ECM
P2125
(05-257)Throttle/Pedal Position Sensor/
Switch ºEº CircuitAccelerator pedal position sensor
ECM
P2127
(05-257)Throttle/Pedal Position Sensor/
Switch ºEº Circuit Low Input
Accelerator pedal position sensor
Open in VCP2 circuit
VPA2 circuit open or ground short
ECM
P2128
(05-257)Throttle/Pedal Position Sensor/
Switch ºEº Circuit High InputAccelerator pedal position sensor
Open in EPA2 circuit
ECM
P2135
(05-102)Throttle Pedal Position Sensor/
Switch ºAº/ºBº Voltage Correla-
tion
Same as DTC No. P0120
P2138
(05-257)Throttle Pedal Position Sensor/
Switch ºDº/ºEº Voltage Correla-
tionVPA and VPA2 circuit are short circuited
Accelerator pedal position sensor
ECM
P2195*3
(05-269)
Oxygen (A/F) Sensor Signal
Stuck Lean (Bank 1 Sensor 1)
Open or short in A/F sensor circuit
A/F sensor
A/F sensor heater
EFI relay
Open or short in A/F sensor heater and EFI relay circuits
Air induction system
Fuel pressure
Injector
ECM
P2196*3
(05-269)
Oxygen (A/F) Sensor Signal
Stuck Rich (Bank 1 Sensor 1)Same as DTC No. P2195
Page 2107 of 2572

05-54
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
244 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)P2238*
3
(05-282)
Oxygen Sensor Pumping Current
Circuit Low (for A/F sensor)
(Bank 1 Sensor 1)
Open or short in A/F sensor circuit
A/F sensor
A/F sensor heater
EFI relay
Open or short in A/F sensor heater and EFI relay circuits
ECM
P2239*3
(05-282)
Oxygen Sensor Pumping Current
Circuit High (for A/F sensor)
(Bank 1 Sensor 1)
Same as DTC No. P2238
P2252*3
(05-282)
Oxygen Sensor Reference
Ground Circuit Low (for A/F sen-
sor) (Bank 1 Sensor 1)
Same as DTC No. P2238
P2253*3
(05-282)
Oxygen Sensor Reference
Ground Circuit High (for A/F sen-
sor) (Bank 1 Sensor 1)
Same as DTC No. P2238
P2401
(05-288)Evaporative Emission System
Leak Detection Pump Control
Circuit LowPump module
Connector/Wire harness (Pump module - ECM)
ECM
Leakage from EVAP system
P2402
(05-288)Evaporative Emission System
Leak Detection Pump Control
Circuit HighPump module
Connector/Wire harness (Pump module - ECM)
ECM
P2419
(05-294)Evaporative Emission System
Switching Valve Control Circuit
LowPump module
Connector/Wire harness (Pump module - ECM)
ECM
P2420
(05-294)Evaporative Emission System
Switching Valve Control Circuit
HighPump module
Connector/Wire harness (Pump module - ECM)
ECM
Leakage from EVAP system
P2610
(05-300)ECM/PCM Internal Engine Off
Timer PerformanceECM
P2716
(05-974)Pressure Control Solenoid ºDº
ElectricalElectronic controlled automatic transmission (ECT)
P2A00
(05-302)A/F Sensor Circuit Slow Re-
sponse (Bank 1 Sensor 1)
Open or short in A/F sensor circuit
A/F sensor
A/F sensor heater
EFI relay
Open or short in A/F sensor heater and EFI relay circuits
Air induction system
Fuel pressure
Injector
ECM
P2769
(05-978)DSL Solenoid Circuit LowElectronic controlled automatic transmission (ECT)
P2770
(05-978)DSL Solenoid Circuit HighElectronic controlled automatic transmission (ECT)
B2799
(05-2010)Engine Immobilizer System Mal-
functionImmobilizer system-
HINT:
*
1: MIL illuminates
*
2: MIL illuminates or flashes continuously
*
3: Although the title (DTC description) says ºoxygen sensorº, this DTC is related to the ºA/F sensorº.
Page 2108 of 2572

320WC-05
F46187
Brake Fluid
F46188
F46189
C80826
32-4
- BRAKEBRAKE FLUID
3117 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
BRAKE FLUID
BLEEDING
HINT:
If any work is performed on the brake system or if air in the brake lines is suspected, bleed the air out of the
brake system.
NOTICE:
Wash brake fluid off immediately if it adheres to any painted surface.
1. FILL RESERVOIR WITH BRAKE FLUID
Fluid: SAE J1703 or FMVSS No. 116 DOT3
2. BLEED MASTER CYLINDER
HINT:
If the master cylinder has been disassembled or if the reservoir
becomes empty, bleed the air out of the master cylinder.
(a) Using SST, disconnect the brake lines from the master
cylinder.
SST 09023-00101
(b) Slowly depress and hold the brake pedal.
(c) Cover the outer holes with your fingers, and release the
brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
(e) Using SST, connect the brake lines from the master cylin-
der.
SST 09023-00101
Torque: 15 NVm (155 kgfVcm, 11 ftVlbf)
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the bleeder plug.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal depressed.
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid is completely
bled out.
(e) Tighten the bleeder plug completely.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
Page 2109 of 2572

G23361DLC3
Hand-held Tester
C80826
- BRAKEBRAKE FLUID
32-5
3118 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(f) Repeat the previous procedures for each wheel to bleed
the air out of the brake line.
4. BLEED BRAKE ACTUATOR ASSY
NOTICE:
After bleeding the air from the brake system, if the height
or feel of the brake pedal cannot be obtained, perform air
bleeding in the brake actuator assy with a hand-held tester
by following the procedures below.
(a) Depress the brake pedal more than 20 times with the en-
gine off.
(b) Connect the hand-held tester to the DLC3, then turn the
ignition switch to the ON position.
NOTICE:
Do not start the engine.
(c) Select ºAIR BLEEDINGº on the hand-held tester.
HINT:
Please refer to the hand-held tester operator's manual for fur-
ther details.
(d) Bleed the air out of the regular brake line when ºStep 1:
Increaseº appears on the hand-held tester display.
NOTICE:
Bleed the air by following the steps displayed on the
hand-held tester.
Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.
(1) Connect the vinyl tube to either one of the bleeder
plugs.
(2) Depress the brake pedal several times, then loosen
the bleeder plug connected to the vinyl tube with the
pedal depressed.
(3) When fluid stops coming out, tighten the bleeder
plug and release the brake pedal.
(4) Repeat (2) and (3) until all the air in the fluid is com-
pletely bled out.
(5) Tighten the bleeder plug completely.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
(6) Repeat the above procedures for each wheel to
bleed the air out of the brake line.
(e) Bleed the air out of the suction line when ºStep 2: Inhala-
tionº appears on the hand-held tester display.
NOTICE:
Bleed the air by following the steps displayed on the
hand-held tester.
Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.
Page 2110 of 2572

F47332
F47333
Hold 32-6
- BRAKEBRAKE FLUID
3119 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(1) Connect the vinyl tube to the bleeder plug at the
right front wheel or the right rear wheel and loosen
the bleeder plug.
(2) Operate the brake actuator assy to bleed the air us-
ing the hand-held tester.
NOTICE:
This operation stops automatically after 4 seconds.
At this time, be sure to release the brake pedal.
(3) Check if the operation has stopped by referring to
the hand-held tester display.
(4) Repeat (2) and (3) until all air in the fluid is complete-
ly bled out.
(5) Tighten the bleeder plug completely.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
(6) Repeat the above procedures to bleed the air out of
the brake line for each wheel.
(f) Bleed the air out of the pressure reduction line when ºStep
3: Decreaseº appears on the hand-held tester display.
NOTICE:
Bleed the air by following the steps displayed on the
hand-held tester.
Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.
(1) Connect a vinyl tube to either one of the bleeder
plugs.
(2) Loosen the bleeder plug.
(3) Using the hand-held tester, operate the brake ac-
tuator assy, completely depress the brake pedal
and keep it.
NOTICE:
The operation stops automatically after 4 seconds.
When performing this procedure continuously, set an
interval of at least 20 seconds.
When the operation is complete, the brake pedal goes
down slightly. This is a nomal phenomenon caused
when the solenoid opens.
During this procedure, the pedal will feel heavy, but
completely depress it so that the brake fluid comes
out from the bleeder plug.
Be sure to keep depressing the brake pedal. Do not
depress and release the pedal repeatedly.
Page 2111 of 2572

F47334
Release
C80826
- BRAKEBRAKE FLUID
32-7
3120 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(4) Tighten the bleeder plug, then release the brake
pedal.
(5) Repeat (2) to (4) until all the air in the fluid is com-
pletely bled out.
(6) Tighten the bleeder plug completely.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
(7) Repeat the above procedures for each wheel to
bleed the air out of the brake line.
(g) Bleed the air out of the regular brake line again when
ºStep 4: Increaseº appears on the hand-held tester dis-
play.
NOTICE:
Bleed the air by following the steps displayed on the
hand-held tester.
Make sure that the brake fluid in the master cylinder
reservoir tank does not become empty.
(1) Connect the vinyl tube to either one of the bleeder
plugs.
(2) Depress the brake pedal several times, then loosen
the bleeder plug connected to the vinyl tube with the
pedal depressed.
(3) When fluid stops coming out, tighten the bleeder
plug, then release the brake pedal.
(4) Repeat (2) and (3) until all the air in the fluid is com-
pletely bled out.
(5) Tighten the bleeder plug completely.
Torque: 8.3 NVm (85 kgfVcm, 73 in.Vlbf)
(6) Repeat the above procedures for each wheel to
bleed the air out of the brake line.
5. CHECK FLUID LEVEL IN RESERVOIR
(a) Check the fluid level and add fluid if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3
Page 2112 of 2572
The sections shown in the figure below are filled with foamed material to provide noise insulation.
After repairing these sections or their peripheries, refill with foamed materials
HINT:
1) Use the service holes located on the reverse side of the body panel to refill with foamed materials.
2) When handling foamed material, follow the directions of the material's manufacturer.
F16737
PAINT COATINGPC-8
FOAMED MATERIAL APPLICATION AREAS