2001 TOYOTA HIGHLANDER service

01-10
- INTRODUCTIONREPAIR INSTRUCTION
10 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER
HINT:
The HIGHLANDER is equipped with a Supplemental Restraint System (SRS) and seat belt pretensioner.
Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly
deploy during servicing and lead to serious injury.
Furthermore, if a mistake is made when servicing the SRS, it is possible that the SRS may fail to operate
properly. Before servicing (including removal or installation of parts, inspection or replacement), be sure to
read the following section carefully.
(a) GENERAL NOTICE
(1) Malfunction symptoms of the SRS are difficult to confirm so the Diagnostic Trouble Codes (DTCs)
become the most important source of information when troubleshooting. When troubleshooting
the SRS, always check the DTCs before disconnecting the battery (see page 05-1215).
(2) To avoid serious injury, servicing the SRS must be started at least 90 seconds after:

The ignition switch is turned to the LOCK position.

The negative (-) terminal cable is disconnected from the battery.
(The SRS is equipped with a back-up power source. If work is started within 90 seconds of dis-
connecting the negative (-) terminal cable from the battery, the SRS may deploy.)
Disconnecting the negative (-) terminal cable will erase the memory of all vehicle systems. Initial-
ize the systems after disconnecting/reconnecting the cable.
CAUTION:
Never use a back-up power source (battery or other) in an attempt to avoid erasing system memory.
The back-up power source inadvertently may inadvertently power the SRS and cause it to deploy.
(3) In minor collisions where the SRS does not deploy, the horn button assembly, instrument panel
passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly and seat
belt pretensioner should be inspected before further use of the vehicle (see pages 60-19,
60-31, 60-40, 60-46, and 61-8).
(4) Never use SRS parts from another vehicle. When replacing parts, use new parts.
(5) Before repairs, remove the airbag sensor if impacts are likely to be applied to the sensor during
repairs.
(6) Never disassemble and repair the airbag sensor assembly, horn button assembly, instrument
panel passenger airbag assembly, front seat airbag assembly, curtain shield airbag assembly
or seat belt pretensioner.
(7) Replace the center airbag sensor assembly, side airbag sensor assembly, horn button assembly
or the instrument panel passenger airbag assembly, front seat airbag assembly or curtain shield
airbag assembly if: 1) damage has occurred from being dropped, or 2) cracks, dents or other
defects in the case, bracket or connector are present.
(8) Do not directly expose the airbag sensor assembly, the horn button assembly, the instrument
panel passenger airbag assembly, front seat airbag assembly, the curtain shield airbag assem-
bly or the seat belt pretensioner to hot air or flames.
(9) Use a voltmeter/ohmmeter with high impedance (10 kW/V minimum) for troubleshooting electri-
cal circuits.
(10) Information labels are attached to the SRS components. Follow the instructions on the labels.
(11) After work on the SRS is completed, check the SRS warning light (see page 05-1207).

- INTRODUCTIONTERMS
01-47
47 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module-
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel-Shutoff-
ISCIdle Speed Control-
KSKnock SensorKnock Sensor
MAFMass AirflowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure-
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface Temperature-
MVZManifold Vacuum Zone-
NVRAMNon-V olatile Random Access Memory-
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn-Board DiagnosticOn-Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OLOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module-
PNPPark/Neutral Position-
PROMProgrammable Read Only Memory-
PSPPower Steering Pressure-
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module-
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE-ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter-
SRIService Reminder Indicator-
SRTSystem Readiness Test-
STScan Tool-
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter

0305U-04
6N
8N
10N
11 N
12N
B06432
Nut Type
Present Standard
Hexagon Nut
Cold Forging Nut Cutting Processed NutClass
4N
5N (4T)
6N
7N (5T)
8N
10N (7T)
11 N
12N Old Standard Hexagon Nut
No Mark (w/ Washer)No Mark
*
No Mark (w/ Washer)
No Mark
No Mark
*: Nut with 1 or more marks on one side surface of the nut.
- SERVICE SPECIFICATIONSSTANDARD BOLT
03-3
124 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
HOW TO DETERMINE NUT STRENGTH
HINT:
Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas-
sification number when tightening parts with a bolt and nut.
Example: Bolt = 4T
Nut = 4N or more

xTo search for a destination, the switches
below perform the following operations.
1Addressº switch
You can input the house number and the
street address by using the input keys.
22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2POI Nameº switch
You can select one of the many POIs (Points
of Interest) that have been already stored in
the system's database. 26. . . . . . . . . . . . . .
3POI Categoryº switch
You can select a destination from the POI
category. 29. . . . . . . . . . . . . . . . . . . . . . . . . .
4Previousº switch
You can select a destination from any of the
last 99 previously set destinations and from
the previous starting point. 34. . . . . . . . . . .
5Memoryº switch
You can select the location from those regis-
tered as the Memory pointsº. (To register
memory points, see page 66.) 33. . . . . . . .
6Emergencyº switch
You can select one of the three categories of
emergency service points that have been al-
ready stored in the system's database.
32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ð Destinationº screen

031WC-01
03-36
- SERVICE SPECIFICATIONSREAR SUSPENSION
157 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
REAR SUSPENSION
SERVICE DATA
Rear wheel align-
Toe-in (total)
No.2 lower suspension arm length difference: FF
4WD
0
18'
12' (0.3

0.2
, 3
2 mm, 0.12
0.08 in.)
1.5 mm (0.06 in.) or less
1.0 mm (0.04 in.) or less
Rear wheel align
mentCamber
FF
4WD
Right-left error
-1°20' ± 45' (-1.33° ± 0.75°)
-0°45' ± 45' (-0.75° ± 0.75°)
45' (0.75°) or less
Rear SuspensionStabilizer link ball joint turning torque1.0 NVm (10 kgfVcm, 9 in.Vlbf) or less

0305T-04
03-2
- SERVICE SPECIFICATIONSSTANDARD BOLT
123 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
SPECIFIED TORQUE FOR STANDARD BOLTS
Specified torque
ClassDiameter
mm
Pitch
mmHexagon head boltHexagon flange boltClassmmmmN´mkgf´cmft´lbfN´mkgf´cmft´lbf
4T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.55
12.5
26
47
74
11 555
130
260
480
760
1,15048 in.´lbf
9
19
35
55
836
14
29
53
84
-60
145
290
540
850
-52 in.´lbf
10
21
39
61
-
5T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.56.5
15.5
32
59
91
14065
160
330
600
930
1,40056 in.´lbf
12
24
43
67
1017.5
17.5
36
65
100
-75
175
360
670
1,050
-65 in.´lbf
13
26
48
76
-
6T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.58
19
39
71
11 0
17080
195
400
730
1,100
1,75069 in.´lbf
14
29
53
80
1279
21
44
80
125
-90
210
440
810
1,250
-78 in.´lbf
15
32
59
90
-
7T
6
8
10
12
14
161
1.25
1.25
1.25
1.5
1.510.5
25
52
95
145
23011 0
260
530
970
1,500
2,3008
19
38
70
108
16612
28
58
105
165
-120
290
590
1,050
1,700
-9
21
43
76
123
-
8T
8
10
121.25
1.25
1.2529
61
11 0300
620
1,10022
45
8033
68
120330
690
1,25024
50
90
9T
8
10
121.25
1.25
1.2534
70
125340
710
1,30025
51
9437
78
140380
790
1,45027
57
105
10T
8
10
121.25
1.25
1.2538
78
140390
800
1,45028
58
10542
88
155430
890
1,60031
64
11 6
11 T
8
10
121.25
1.25
1.2542
87
155430
890
1,60031
64
11 647
97
175480
990
1,80035
72
130

120E5-01
A88556
Carbon Filter
Charcoal Canister Filter
VSV for CCV ECM
Charcoal Canister Refueling Valve
Restrictor Passage Vapor Pressure Sensor
Fuel Tank
Purge Line
Fresh Air Line EVAP
Service Port Purge ValveAir Cleaner 12-16
- EMISSION CONTROLEMISSION CONTROL SYSTEM (3MZ-FE)
2474 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
SYSTEM DIAGRAM
The emission control system is determined by the ECM based on signals from various sensors.

0304O-04
03-32
- SERVICE SPECIFICATIONSSTARTING & CHARGING
153 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
TORQUE SPECIFICATION
2AZ-FE
Part TightenedNVmkgfVcmftVlbf
Starter assy
Starter assy x Engine3737727
Starter wire x Terminal 30 of starter9.81007.0
Starter drive housing assy x Magnet switch assy7.57666 in.Vlbf
Starter commutator end frame assy x Starter drive housing assy6.06153 in.Vlbf
Lead wire of starter yoke x Terminal C of magnet switch assy101027.0
Battery clamp x Battery clamp bolt5.55649 in.Vlbf
Cable x Battery terminal3.53631 in.Vlbf
Generator assy (100A)
Generator assy x Engine M8
M1021
52214
53015
38
Generator wire x Generator assy9.81007.0
Generator rectifier end frame x Drive end frame assy5.85951 in.Vlbf
Generator brush holder assy x Generator rectifier end frame1.81816 in.Vlbf
Generator rear end cover x Generator rectifier end frame4.64741 in.Vlbf
Retainer plate x Drive end frame assy generator2.32320 in.Vlbf
Generator pulley x Generator rotor assy11 01,12281
Generator assy (130A)
Generator assy x Engine M8
M1021
52214
53015
38
Generator wire x Generator assy9.81007.0
Generator rectifier end frame x Drive end frame assy5.85951 in.Vlbf
Generator brush holder assy x Generator rectifier end frame1.81816 in.Vlbf
Generator rear end cover x Generator rectifier end frame4.64741 in.Vlbf
Retainer plate x Drive end frame assy generator2.32320 in.Vlbf
Generator pulley x Generator rotor assy11 01,12281
3MZ-FE
Part TightenedNVmkgfVcmftVlbf
Starter assy
Starter assy x Engine3737727
Starter wire x Terminal 30 of starter9.81007.0
Starter drive housing assy x Magnet switch assy7.57666 in.Vlbf
Starter commutator end frame assy x Starter drive housing assy6.06153 in.Vlbf
Lead wire of starter yoke x Terminal C of magnet switch assy101027.0
Battery clamp x Battery clamp bolt5.55649 in.Vlbf
Cable x Battery terminal3.53631 in.Vlbf
Generator assy (100A)
Generator assy x Generator bracket No. 25859243
Generator assy x Generator belt adjusting bar1818413
Generator wire x Generator assy9.81007.0
Generator rectifier end frame x Drive end frame assy5.85951 in.Vlbf
Generator brush holder assy x Generator rectifier end frame1.81816 in.Vlbf
Generator rear end cover x Generator rectifier end frame4.64741 in.Vlbf
Retainer plate x Drive end frame assy generator2.32320 in.Vlbf
Generator pulley x Generator rotor assy11 01,12281
Generator assy (130A)
Generator assy x Generator bracket No. 25859243
Generator assy x Generator belt adjusting bar1818413
Generator wire x Generator assy9.81007.0