2001 TOYOTA HIGHLANDER engine

- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-769
959 Author
: Date
: ItemDiagnostic Note Normal Condition Measurement Item /
Range (Display)
SFLHABS solenoid (SFLH) / ON
or OFFON : Operate-
SRRR (SRR)ABS solenoid (SRRR
(SRR)) / ON or OFFON : Operate-
SRRH (SRH)ABS solenoid (SRRH
(SRH)) / ON or OFFON : Operate-
SRLRABS solenoid (SRLR) / ON
or OFFON : Operate-
SRLHABS solenoid (SRLH) / ON
or OFFON : Operate-
SMF (BA-SOL)TRAC solenoid (SMF) /
ON or OFFON : Operate-
SMRTRAC solenoid (SMR) /
ON or OFFON : Operate-
THROTTLEThrottle position sensor/
Min.: 0 deg, Max.: 125 deg
Release accelerator pedal:
Approx. 0 deg.
Depress accelerator pedal:
Approx. 90 deg.
-
ENGINE SPD
Engine Speed/
Min.: 0 rpm, Max.: 6,000
rpm
Actual engine speed-
VEHICLE SPD
Maximum wheel speed
sensor reading / min.: 0
km/h (0 MPH), max.: 326
km/h (202 MPH)
Actual vehicle speedSimilar speed as indicated
on speedometer
YAW RATE
Yaw rate sensor/
Min.: -128 deg/s, Max.:
128 deg/sMin.: -128 deg/s
Max.: 128 deg/s-
YAW ZERO VALUE
Memorized zero value/
Min.: -128 deg/s, Max.:
128 deg/sMin.: -128 deg/s
Max.: 128 deg/s-
STEERING ANG
Steering sensor/
Min.: -1152 deg,
Max.: 1150.875 degLeft turn: Increase
Right turn: Decrease-
MAS CYL PRS 1
Master cylinder pressure
sensor 1 reading / min.: 0
V, max.: 5 VWhen brake pedal is re-
leased : 0.3 to 0.9 VReading increases when
brake pedal is depressed
TEST MODETest mode / NORMAL or
TESTNORMAL : Normal mode
TEST : During test mode-
#CODESNumber of DTC recorded /
min.: 0, max.: 255Min.: 0, max.: 39-

F02135
Start Position
End PositionWithin ± 5°
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-773
963 Author
: Date
:

If master cylinder pressure sensor check can not be com-
pleted, do not depress the brake pedal frequently. It may
further reduce negative pressure and make the sensor
check difficult to complete.

If the negative pressure is insufficient, master cylinder
pressure sensor check may not be completed. In this
case, idle the engine to get enough negative pressure.

If the brake pedal is depressed while engine is stopped,
negative pressure may become insufficient and the BRL
may come on. (It runs the motor and performs incorrect
control.)
(c) Check the yaw rate sensor:
(1) Shift the shift lever to the D position and drive the
vehicle at a speed of approx. 3 mph (5 km/h), turn
the steering wheel either to the left or right 90° or
more, and maintain a 180° circular drive for the ve-
hicle.
(2) Stop the vehicle and shift the shift lever to the P
position, and check that the skid control buzzer
sounds for 3 sec.
NOTICE:
Deceleration sensor check should be completed before
performing speed sensor check.
HINT:

If the skid control buzzer sounds, the sensor check is
completed normally.

If the skid control buzzer does not sound, check the skid
control buzzer circuit (See page 05-866), then perform
the sensor check again. If the skid control buzzer still does
not sound, there is a malfunction in the VSC sensor, so
check for DTCs.

Drive the vehicle in a 180° circle. At the end of the turn,
ensure that the vehicle is exactly 180° within a tolerance
of ± 5°, and facing the other direction from its original
start position.

Do not spin the wheels.
(d) Check the speed sensor signal:
(1) Drive the vehicle straight forward at speed of 28
mph (45 km/h) or higher for several seconds and
check that the ABS warning light goes off.
HINT:
The sensor check may not be completed if the vehicle has its
wheels spun or its steering wheel turned during this check.
(2) Stop the vehicle.
NOTICE:

Before performing speed sensor check, complete
master cylinder pressure sensor and deceleration
sensor checks.

F02135
Start Position
End PositionWithin ± 5° 05-776
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
966 Author
: Date
:
(c) Check the yaw rate:
(1) Shift the shift lever to the D position and drive the
vehicle at a speed of approx. 3 mph (5 km/h), and
maintain a 180° circular drive for the vehicle.
(2) Stop the vehicle and shift the shift lever to the P
position, and check that the skid control buzzer
sounds for 3 seconds.
HINT:

If the skid control buzzer sounds, the sensor check is
completed normally.

If the skid control buzzer does not sound, check the skid
control buzzer circuit (See page 05-866), then perform
the sensor check again. If the skid control buzzer still does
not sound, there is a malfunction in the VSC sensor, so
check for DTC.

Drive the vehicle in a 180° circle. At the end of the turn,
ensure that the vehicle is exactly 180° within a tolerance
of ± 5°, and facing the other direction from its original
start position.

Do not spin the wheels.
(d) Check the speed sensor:
(1) Drive the vehicle straight forward at the speed of 28
mph (45 km/h) or higher for several seconds and
check that the ABS warning light goes off.
HINT:
The sensor check may not be completed if the vehicle has its
wheels spun or its steering wheel turned during this check.
(2) Stop the vehicle.
(e) Read the DTC following the tester screen.
HINT:

Refer to the hand-held tester operator's manual for fur-
ther details.

If the check result is OK, the ABS warning light link goes
off when the brake pedal is once depressed.
9. IF NECESSARY, PERFORM ZERO POINT CALIBRA-
TION OF YAW RATE SENSOR AND/OR BRAKE AC-
TUATOR ASSY (USING SST CHECK WIRE)
NOTICE:

While obtaining the zero point, do not tilt, move or
shake the vehicle but keep it in a stationary condition.
(Do not start the engine.)

Be sure to perform the operation on a level surface
(within an inclination of 1 %).
(a) Check that the steering wheel is in the straight-ahead
position and shift the shift lever to the P position.
(b) Clear the zero point calibration:
HINT:
When replacing the yaw rate sensor only (not replace the brake
actuator assy).
(1) Turn the ignition switch to the ON position.

C52361
DLC3
Ts
CG
F46259
- DIAGNOSTICSABS WITH EBD & BA & TRAC & VSC SYSTEM
05-777
967 Author
: Date
:
(2) Using SST, connect and disconnect terminals Ts
and CG of the DLC3 4 times or more within 8 se-
conds.
SST 09843-18040
(3) Remove the SST from the terminals of the DLC3.
(c) Obtain the zero point calibration:
(1) Turn the ignition switch off.
(2) Using SST, connect terminals Ts and CG of the
DLC3.
SST 09843-18040
(3) Turn the ignition switch to the ON position.
(4) Keep the vehicle in a stationary condition on a level
surface for 2 seconds or more.
(5) Check that the VSC warning light blinks.
HINT:
If the VSC warning light does not blink, perform the zero point
calibration again.
(d) Remove the SST from the terminals of the DLC3.
SST 09843-18040
(e) Turn the ignition switch off.
10. IF NECESSARY, PERFORM ZERO POINT CALIBRATION OF YAW RATE SENSOR AND/OR
BRAKE ACTUATOR ASSY (USING HAND-HELD TESTER)
NOTICE:

While obtaining the zero point, do not tilt, move or shake the vehicle but keep it in a stationary
condition. (Do not start the engine.)

Be sure to perform the operation on a level surface (within an inclination of 1 %).
(a) Check that the steering wheel is in the straight-ahead position and shift the shift lever to the P position.
(b) Connect the hand-held tester to the DLC3.
(c) Turn the ignition switch to the ON position.
(d) Perform the reset memory by following the prompts on the tester screen.
HINT:
When replace the yaw rate sensor only (not replace the brake actuator assy).
[System Selection Screen]
ºDIAGNOSISº - ºOBD/MOBDº - Select the vehicle - ºABS/VSCº - ºRESET MEMORYº
(e) Perform the signal check (test mode) by following the prompts on the tester screen.
[System Selection Screen]
ºDIAGNOSISº - ºOBD/MOBDº - Select the vehicle - ºABS/VSCº - ºSIGNAL CHECKº
(f) Obtain zero point of the yaw rate sensor and deceleration sensor:
(1) Keep the vehicle in a stationary condition on a level surface for 2 seconds or more.
(2) Check that the VSC warning light blinks.

I30328
w/o Navigation System
I38758
w/ Navigation System
I30337
ECU-B Fuse Engine Room J/B
F46779
- DIAGNOSTICSAIR CONDITIONING SYSTEM
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: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
(c) If the slower display is desired, press the FRONT DEF
switch and change it to stepped operation. Each time the
FRONT DEF switch is pressed, the display changes by 1
step.
4. CLEARING DTC
(a) To clear diagnostic trouble code, there are 2 ways.
(1) During sensor check, press the FRONT DEF switch
and REAR DEF switch at the same time.
(2) Pull the ECU-B fuse in engine room J/B for 20 sec.
or longer to clear the DTC memory.
5. DTC CHECK USING HAND-HELD TESTER
(a) Connect the hand-held tester to the DLC3.
(b) Power switch ON (ready).
(c) Read the DTC following the prompts on the tester screen.
Please refer to the hand-held tester operator's manual
for further details.
(d) Clear the DTCs.
HINT:
After repairing the malfunctions, clear the DTC.
(1) Connect the hand-held tester to DLC3.
(2) Turn the ignition switch to the ON position.
(3) Erase the DTCs following the prompts on the tester
screen.
HINT:
Refer to the hand-held tester operator's manual for further de-
tails.

3 2 1 45678
9 1 0 111 21 31 41 51 6
DLC3
A04550
- DIAGNOSTICSAIR CONDITIONING SYSTEM
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1311 Author
: Date
:
2005 HIGHLANDER REPAIR MANUAL (RM1144U)
7. CHECK DLC3
(a) The vehicle's ECM uses ISO 9141-2 for communication.
The terminal arrangement of the DLC3 complies with
SAEJ1962 and matches the ISO 9141-2 format.
Terminal No.Connection/Voltage or ResistanceCondition
7Bus + Line/Pulse generationDuring transmission
4Chassis Ground - Body Ground/1 W or lessAlways
5Signal Ground - Body Ground/1 W or lessAlways
16Battery Positive - Body Ground/9 to 14 VAlways
8. DATA LIST
HINT:
From the DATA LIST displayed on the hand-held tester, you can read the values of the displays, sensors,
actuators and so on without parts removal. Reading the DATA LIST as the first step of troubleshooting is
one way to shorten labor time.
(a) Connect the hand-held tester to the DLC3.
(b) Turn the ignition switch to the ON position.
(c) From the display on the tester, select the ºDATA LISTº.
ALL:
ItemMeasurement Item / Display
(Range)Normal ConditionDiagnostic Note
A/C SIGA/C signal / ON or OFFA/C ON: ON-
A C:
ItemMeasurement Item/Display
(Range)Normal ConditionDiagnostic Note
ROOM TEMP
Room temperature sensor
/min.: -6.5C (20.3F)
max.: 57.25C (135.05F)
Actual room temperature-
AMBI TEMP SENS
Ambient temperature sensor
/min.: -23.3C (-9.94F)
max.: 65.95C (150.71F)
Actual ambient temperature-
AMBI TEMP
Adjusted ambient temperature
/min.: -30.8C (-23.44F)
max.: 50.8C (123.44F)
Actual ambient temperature-
EVAP TEMP
Evaporator temperature sensor
/min.: -29.7C (-21.46F)
max.: 59.55C (139.19F)
Actual evaporator temperature-
SOLAR SENS-DSolar sensor (Driver side)
/min.: 0 max.: 255Changes depending on brightness
(Driver side)-
COOLANT TEMP
Engine coolant temperature
/min.: 1.3C (34.34F)
max.: 90.55C (194.99F)
Actual engine coolant temperature-
SET TEMP-D
Set temperature
(Driver side)
/min.: 0 max.: 255Actual set temperature
(Driver side)-
A/M DAMP POS-D
Air mix damper position
(Driver side)
/min.: -14% max.: 113.5%Changes depending on the set
temperature (Driver side)-

F10016A
F10017A
F10018A
F10019A
F10020A
Body
Measurement
Diagrams
WRONG
CORRECT WRONG
Tip Cutter
Old
Spot
LocationsNew Spot
Locations
INTRODUCTIONIN-12
3. INSTALLATION
(a) PRE-WELDING MEASUREMENTS
(1) Always take measurements before installing under-
body or engine components to insure correct assem-
bly. After installation, confirm proper fit.
(b) WELDING PRECAUTIONS
(1) The number of welding spots should be as follows.
Spot weld: 1.3 X No. of manufacturer's spots.
Plug weld: More than No. of manufacturer's plugs.
(2) Plug welding should be done with a MIG (Metal Inert
Gas) welder. Do not gas weld or braze panels at areas
other than specified.
(c) POST-WELDING REFINISHING
(1) Always check the welded spots to insure they are se-
cure.
(2) When smoothing out the weld spots with a disc grind-
er, be careful not to grind off too much as this would
weaken the weld.
(d) SPOT WELD LOCATIONS
(1) Try to avoid welding over previous spots.
(e) SPOT WELDING PRECAUTIONS
(1) The shape of the welding tip point has an effect on the
strength of the weld.
(2) Always insure that the seams and welding tip are free
of paint.

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