Page 2385 of 2572

051ZK-13
- DIAGNOSTICSSFI SYSTEM (2AZ-FE)
05-31
221 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
PROBLEM SYMPTOMS TABLE
SymptomSuspected AreaSee Page
Engine does not crank (does not start)
1. Starter
2. STARTER relay
3. PNP switch19-12
19-12
40-6
No initial combustion (does not start)
1. ECM power source circuit
2. Fuel pump control circuit
3. ECM05-312
05-349
01-36
No complete combustion (does not start)1. Fuel pump control circuit05-349
Difficult to start (engine cranks normally)
1. Starter signal circuit
2. Fuel pump control circuit
3. Compression05-235
05-349
14-1
Difficult to start with cold engine1. Starter signal circuit
2. Fuel pump control circuit05-235
05-349
Difficult to start with hot engine1. Starter signal circuit
2. Fuel pump control circuit05-235
05-349
High engine idle speed (poor idling)1. A/C signal circuit (Compressor circuit)
2. ECM power source circuit05-1 190
05-312
Low engine idle speed (poor idling)1. A/C signal circuit (Compressor circuit)
2. Fuel pump control circuit05-1 190
05-349
Rough idling (poor idling)1. Compression
2. Fuel pump control circuit14-1
05-349
Hunting (poor idling)1. ECM power source circuit
2. Fuel pump control circuit05-312
05-349
Hesitation/Poor acceleration (poor driveability)1. Fuel pump control circuit
2. A/T faulty05-349
05-904
Surging (poor driveability)1. Fuel pump control circuit05-349
Engine stalls soon after starting1. Fuel pump control circuit05-349
Engine stalls during A/C operation1. A/C signal circuit (Compressor circuit)
2. ECM05-1 190
01-36
Unable to refuel/Difficult to refuel1. ORVR system
Page 2386 of 2572

7101E-06
- INSTRUMENT PANEL/METERCOMBINATION METER
71-1
3592 Author: Date:
COMBINATION METER
PROBLEM SYMPTOMS TABLE
Warning Lights:
SymptomSuspect AreaSee page
Check Engine warning light does not come on.
7. ECM
8. Wire Harness or Connector
9. Combination Meter Assy05-5
05-366
-
71-18
Discharge warning light does not come on.
1. ECM
2. Wire Harness or Connector
3. Combination Meter Assy05-5
05-366
-
71-18
Brake warning light does not come on.
1. Skid control ECU
2. Wire Harness or Connector
3. Combination Meter Assy05-761
-
71-18
ABS warning light does not come on.
1. ABS ECU
2. Wire Harness or Connector
3. Combination Meter Assy05-761
-
71-18
SRS warning light does not come on.
1. Airbag Sensor Assy Center
2. Wire Harness or Connector
3. Combination Meter Assy05-1200
-
71-18
Open Door warning light does not come on.
1. Refer to troubleshooting
2. Wire Harness or Connector
3. Combination Meter Assy05-1601
-
71-18
Fuel Level warning light does not come on.
1. Refer to troubleshooting
2. Wire Harness or Connector
3. Combination Meter Assy05-1893
-
71-18
Low Oil Pressure warning light does not come on.
1. Low Oil Pressure Warning Switch
2. Wire Harness or Connector
3. Combination Meter Assy71-3
-
71-18
Driver's seat belt warning light does not come on.
1. Refer to troubleshooting
2. Wire Harness or Connector
3. Combination Meter Assy05-1898
-
71-18
ºOIL LEVELº warning light does not come on.
1. Low Oil Level Sensor
2. Wire Harness or Connector
3. ECM
4. Combination Meter Assy05-5
05-366
-
05-5
05-366
71-18
ºTIRE AIR PRESSº warning light does not come on.
1. Wire Harness or Connector
2. Skid Control ECU
3. Combination Meter Assy-
05-761
71-18
Indicator Lights:
SymptomSuspect AreaSee page
Turn indicator light does not come on.
1. Turn Signal and Hazard Warning System
2. Wire Harness or Connector
3. Combination Meter Assy05-1533
-
71-18
High Beam indicator light does not come on.
1. Headlight Dimmer Switch
2. Wire Harness or Connector
3. Combination Meter Assy05-1533
-
71-18
Washer level indicator light does not come on.
1. Washer Level Warning Switch
2. Wire Harness or Connector
3. Combination Meter Assy-
-
71-18
Page 2387 of 2572

71-2
- INSTRUMENT PANEL/METERCOMBINATION METER
3593 Author: Date:
MAINT REQD indicator ia blinking or cotinuously illuminated.1. Resetting procedure
2. Combination Meter Assy71-3
71-18
All buzzer (key reminder, tail cancel, Seat belt) does not operate.1. Refer to troubleshooting
2. Combination Meter Assy05-1879
71-18
O/D OFF indicator light does not come on.
1. O/D off Select Switch
2. Wire Harness or Connector
3. Combination Meter Assy-
-
71-18
SLIP indicator light does not come on.
1. Wire Harness or Connector
2. Skid Control ECU
3. Combination Meter Assy-
05-761
71-18
VSC indicator light does not come on.
1. Wire Harness or Connector
2. Skid Control ECU
3. Combination Meter Assy-
05-761
71-18
TRC/TRAC OFF indicator light does not come on.
1. Wire Harness or Connector
2. Skid Control ECU
3. Combination Meter Assy-
05-761
71-18
A/T OIL TEMP indicator light does not come on.
1. Wire Harness or Connector
2. Automatic transmission
3. Combination Meter Assy-
05-883
05-993
71-18
ECT SNOW indicator light does not come on.
1. Wire Harness or Connector
2. ECM
3. Combination Meter Assy-
05-5
05-366
71-18
A/T shift indicator light does not come on.
1. Park Neutral Position Switch
2. Wire Harness or Connector
3. ECM
4. Combination Meter Assy05-883
05-993
-
05-5
05-366
71-18
ºCRUISEº indicator light does not come on.
1. Wire Harness or Connector
2. ECM
3. Combination Meter Assy-
05-5
05-366
71-18
Meter Gauges:
SymptomSuspect AreaSee page
Speedometer does not operate.1. Refer to troubleshooting05-1885
Tachometer does not operate.1. Refer to troubleshooting05-1889
Fuel Gauge does not operate or operates abnormally.1. Refer to troubleshooting05-1893
Water temperature does not operate.1. Refer to troubleshooting05-1896
Clock:
SymptomSuspect AreaSee page
Clock will not operate
Clock loses or gains time
1. Power source or ground
2. Integration control & panel assy05-1 170
05-1 173
05-1 175
71-6
Page 2388 of 2572
2701I-1 1
- REAR SUSPENSIONREAR SUSPENSION SYSTEM
27-1
2949 Author: Date:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
REAR SUSPENSION SYSTEM
PROBLEM SYMPTOMS TABLE
Use the table below, with suspected areas listed in numerical order, to determine the cause of the problem.
Inspect and repair or replace parts as necessary according to the steps on the following pages.
SymptomSuspected AreaSee page
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)-
27-7
27-7
Sways/pitches
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Bent or broken)
3. Shock absorber (Worn)28-1
27-27
27-29
27-7
Rear wheel shimmy
1. Tire (Worn or improperly inflated)
2. Wheel (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Hub bearing (Worn)28-1
28-1
27-7
26-7
27-5
30-3
Abnormal tire wear
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Shock absorber (Worn)
4. Suspension parts (Worn)28-1
26-7
27-5
27-7
-
Page 2389 of 2572
BODY PANEL REPLACEMENT
F16772
220 mm (8.66 in.) 240 mm (9.45 in.)
F16772A
REMOVAL BP-36
QUARTER PANEL (CUT)
REPLACEMENT
Page 2390 of 2572
BODY PANEL REPLACEMENT
F16773
BP-37
Page 2391 of 2572

BODY PANEL REPLACEMENT
F16774
POINT
1 Before temporarily installing the new parts, apply body sealer to the wheel arch.
HINT:
1) Apply body sealer about 5 mm (0.20 in.) from the flange, avoiding any oozing.
2) Apply sealer evenly, about 3 - 4 mm (0.12 - 0.16 in.) in diameter.
2 Inspect the fitting of the front door, luggage compartment door and rear combination light, etc., before welding,
since this affects the appearance of the finish.
PART NAME
[A] Fuel Filler Opening Lid [B] Waterproof Rivets BP-38
INSTALLATION
Temporarily install the new parts and measure each part of the new parts in accordance with the body dimension
diagram. (See the body dimension diagram)
Inspect the fitting of the related parts around the new parts before welding. This affects the appearance of the
finish.
After welding, apply the polyurethane foam to the corresponding parts.
After welding, apply body sealer and under-coating to the corresponding parts.
After applying the top coat layer, apply anti-rust agent to the inside of the necked section structural weld spots.
Page 2392 of 2572
BODY PANEL REPLACEMENT
F16775
BP-39