2001 TOYOTA HIGHLANDER Service Repair Manual

sensor service reset infotainment system spark plugs replace OBD port interior lights

Page 2145 of 2572

TOYOTA HIGHLANDER 2001 Service Repair Manual INTRODUCTION
2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS
(1) The repair procedure for plastic body parts must conform with the type of plastic material.
(2) Plastic body parts are identified by the

INTRODUCTION
2. HANDLING PRECAUTIONS OF PLASTIC BODY PARTS
(1) The repair procedure for plastic body parts must conform with the type of plastic material.
(2) Plastic body parts are identified by the codes in the following table.
(3) When repairing metal body parts adjoining plastic body parts (by brazing, frame cutting, welding, paint-
ing etc.), consideration must be given to the property of the plastic.
CodeMaterial
name
Heat*
resistant
temperature
limit C (F)Resistance to
alcohol or gasolineNotes
AASAcrylonitrile
Acrylic Styrene80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid gasoline and organic
or aromatic solvents.
ABSAcrylonitrile
Butadiene Styrene80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid gasoline and organic
or aromatic solvents.
AESAcrylonitrile
Ethylene Styrene80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid gasoline and organic
or aromatic solvents.
ASA
Acrylonitrile
Styrene
Acrylate80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid gasoline and organic
or aromatic solvents.
CABCellulose
Acetate80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid gasoline and organic
or aromatic solvents.
EPDMEthylene
Propylene100
(212)Alcohol is harmless.
Gasoline is harmless if applied only for
short time in small amounts.Most solvents are harmless
but avoid dipping in gasoline,
solvents, etc.
FRP
Fiber
Reinforced
Plastics180
(356)Alcohol and gasoline are harmless.Avoid alkali.
EVAEthylene
Acetate70
(158)Alcohol is harmless if applid only for short
time in small amounts (e.g., quick wiping
to remove grease).Avoid gasoline and organic
or aromatic solvents.
PAPolyamide
(Nylon)80
(176)Alcohol and gasoline are harmless.Avoid battery acid.
PBTPolybutylene
Terephthalate160
(320)Alcohol and gasoline are harmless.Most solvents are harmless.
PCPolycarbonate120
(248)Alcohol is harmless.
Avoid gasoline brake fluid,
wax, wax removers and
organic solvents. Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.

Page 2146 of 2572

TOYOTA HIGHLANDER 2001 Service Repair Manual INTRODUCTION
CodeMaterial
name
Heat*
resistant
temperature
limit C (F)Resistance to
alcohol or gasolineNotes
PEPolyethylene80
(176)Alcohol and gasoline are harmless.Most solvents are harmless.
PETPo

INTRODUCTION
CodeMaterial
name
Heat*
resistant
temperature
limit C (F)Resistance to
alcohol or gasolineNotes
PEPolyethylene80
(176)Alcohol and gasoline are harmless.Most solvents are harmless.
PETPolyethylene
Terephthalate75
(167)Alcohol and gasoline are harmless.Avoid dipping in water.
PMMAPolymethyl
Methacrylate80
(176)Alcohol is harmless if applied only for
short time in small amounts.Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
POMPolyoxymethylene
(Polyacetal)100
(212)Alcohol and gasoline are harmless.Most solvents are harmless.
PPPolypropylene80
(176)Alcohol and gasoline are harmless.Most solvents are harmless.
PPO
Modified
Polyphenylene
Oxide100
(212)Alcohol is harmless.
Gasoline is harmless if
applied only for quick wiping
to remove grease.
PSPolystyrene60
(140)Alcohol and gasoline are harmless if
applied only for short time in small
amounts.Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
PURPolyurethane80
(176)Alcohol is harmless if applied only for very
short time in small amounts (e.g., quick
wiping to remove grease).Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
PVCPolyvinylchloride
(Vinyl)80
(176)
Alcohol and gasoline are harmless if
applied only for short time in small
amounts (e.g., quick wiping to remove
grease).Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
SANStyrene
Acrylonitrile80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid dipping or immersing
in alcohol, gasoline, solvents
etc.
TPOThermoplastic
Olefine80
(176)Alcohol is harmless.
Gasoline is harmless if applied only for
short time in small amounts.Most solvents are harmless
but avoid dipping in gasoline,
solvents, etc.
TPUThermoplastic
Polyurethane80
(176)Alcohol is harmless if applied only for
short time in small amounts (e.g., quick
wiping to remove grease).Avoid dipping or immersing
in alcohol, gasoline,
solvents, etc.
TSOP
TOYOTA
Super
Olefine Polymer80
(176)Alcohol and gasoline are harmless.Most solvents are harmless.
UPUnsaturated
Polyester11 0
(233)Alcohol and gasoline are harmless.Avoid alkali.
*Temperatures higher than those listed here may result in material deformation during repair.

Page 2147 of 2572

TOYOTA HIGHLANDER 2001 Service Repair Manual INTRODUCTION
3. LOCATION OF PLASTIC BODY PARTS
Parts NameCode
Radiator GrilleABS
HeadlightPC / PP
Front Bumper CoverTSOP
Front Bumper Hole CoverTSOP
Fog LightPC
Front Fender MudguardPP / EPDM
Outer Re

Page 2148 of 2572

TOYOTA HIGHLANDER 2001 Service Repair Manual 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 countr

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.

Page 2149 of 2572

TOYOTA HIGHLANDER 2001 Service Repair Manual 2005 HIGHLANDER (EWD592U)
18
E GLOSSARY OF TERMS AND SYMBOLS
BATTERY
Stores chemical energy and
converts it into electrical energy.
Provides DC current for the autos
various electrical circuits.GROU

2005 HIGHLANDER (EWD592U)
18
E GLOSSARY OF TERMS AND SYMBOLS
BATTERY
Stores chemical energy and
converts it into electrical energy.
Provides DC current for the auto's
various electrical circuits.GROUND
The point at which wiring attaches to
the Body, thereby providing a return
path for an electrical circuit; without a
ground, current cannot flow.
CAPACITOR (Condenser)
A small holding unit for temporary
storage of electrical voltage.HEADLIGHTS
Current flow causes a headlight
filament to heat up and emit light. A
headlight may have either a single
(1) filament or a double (2) filament
1. SINGLE
FILAMENT
CIGARETTE LIGHTER
An electric resistance heating
element.2. DOUBLE
FILAMENT
CIRCUIT BREAKER
Basically a reusable fuse, a circuit
breaker will heat and open if too
much current flows through it.
Some units automatically reset when
cool, others must be manually reset.HORN
An electric device which sounds a
loud audible signal.
DIODE
A semiconductor which allows
current flow in only one direction.IGNITION COIL
Converts low-voltage DC current
into high-voltage ignition current for
firing the spark plugs.
DIODE, ZENERA diode which allows current flow in one
direction but blocks reverse flow only up
to a specific voltage. Above that potential,
it passes the excess voltage. This acts as
a simple voltage regulator.LIGHT
Current flow through a filament
causes the filament to heat up and
emit light.
PHOTODIODE
The photodiode is a semiconductor
which controls the current flow
according to the amount of light.LED (LIGHT EMITTING DIODE)
Upon current flow, these diodes emit
light without producing the heat of a
comparable light.
DISTRIBUTOR, IIA
Channels high-voltage current from
the ignition coil to the individual
spark plugs.METER, ANALOG
Current flow activates a magnetic
coil which causes a needle to move,
thereby providing a relative display
against a background calibration.
FUSEA thin metal strip which burns through
when too much current flows through it,
thereby stopping current flow and
protecting a circuit from damage.
FUSIBLE LINK
METER, DIGITAL
Current flow activates one or many
LED's, LCD's, or fluorescent
displays, which provide a relative or
digital display.
FUEL
FUSIBLE LINK
A heavy-gauge wire placed in high
amperage circuits which burns through on
overloads, thereby protecting the circuit.
The numbers indicate the crosssection
surface area of the wires.(for Medium Current Fuse)
(for High Current Fuse or
Fusible Link)MOTOR
A power unit which converts
electrical energy into mechanical
energy, especially rotary motion.
M

Page 2150 of 2572

TOYOTA HIGHLANDER 2001 Service Repair Manual 2005 HIGHLANDER (EWD592U)
19
E
RELAY
Basically, an electrically operated
switch which may be normally
closed (1) or open (2).
Current flow through a small coil
creates a magnetic field which either
op

2005 HIGHLANDER (EWD592U)
19
E
RELAY
Basically, an electrically operated
switch which may be normally
closed (1) or open (2).
Current flow through a small coil
creates a magnetic field which either
opens or closes an attached switch.
1. NORMALLY
CLOSED
2. NORMALLY
OPEN
SWITCH, MANUAL
Opens and closes
iitth b
SPEAKER
An electromechanical device which
creates sound waves from current
flow.
RELAY, DOUBLE THROW
A relay which passes current
through one set of contacts or the
other.
circuits, thereby
stopping (1) or
allowing (2) current
flow.1. NORMALLY
OPEN
2. NORMALLY
CLOSED
RESISTOR
An electrical component with a fixed
resistance, placed in a circuit to
reduce voltage to a specific value.SWITCH, DOUBLE THROW
A switch which continuously passes
current through one set of contacts
or the other.
RESISTOR, TAPPED
A resistor which supplies two or
more different non adjustable
resistance values.SWITCH, IGNITION
A key operated switch with several
positions which allows various
circuits, particularly the primary
ignition circuit, to become
operational.
RESISTOR, VARIABLE or RHEOSTAT
A controllable resistor with a variable
rate of resistance.
Also called a potentiometer or
rheostat.
SENSOR (Thermistor)
A resistor which varies its resistance
with temperature.SWITCH, WIPER PARK
Automatically returns wipers to the
stop position when the wiper switch
is turned off.
(Reed Switch Type)
SENSOR, SPEED
Uses magnetic impulses to open
and close a switch to create a signal
for activation of other components.TRANSISTOR
A solidstate device typically used as
an electronic relay; stops or passes
current depending on the voltage
applied at ºbaseº.
SHORT PIN
Used to provide an unbroken
connection within a junction block.WIRES
Wires are always drawn as
straight lines on wiring
diagrams.
Crossed wires (1) without a
black dot at the junction are
tj i d
(1) NOT
CONNECTED
SOLENOID
An electromagnetic coil which forms
a magnetic field when current flows,
to move a plunger, etc.
j
not joined;
crossed wires (2) with a
black dot or octagonal ( )
mark at the junction are
spliced (joined)
connections.
(2) SPLICED

Page 2151 of 2572

TOYOTA HIGHLANDER 2001 Service Repair Manual 2005 HIGHLANDER (EWD592U)
314
I GROUND POINT
Brake Warning SW
Skid Control
ECU with
ActuatorFront Fog Light LH
Washer Level
Sensor
Front Turn Signal
Light RH
Headlight RH
(
Low Beam)
Headlight LH
(
L

Page 2152 of 2572

TOYOTA HIGHLANDER 2001 Service Repair Manual 2005 HIGHLANDER (EWD592U)
315
Data Link
Connector 3
Engine Contr ol
Module
A/C Magnetic Clutch
Combination SW Data Link
Connector 3
Ignition Coil and
Igniter No. 1A
A
A
A
A
ED A IM14
RBR
BR
R
BR
BR
J

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